RIO(JB) > 2005 > G 1.

6 DOHC > Suspension System

Suspension System > General Information > Specifications

SPCIFICATIONS
FRONT SUSPENSION SYSTEM
Items Specifications

Type Macpherson strut type

Type Gas

Stroke mm(in) 162.5 (6.39)

Expansion mm(in) 492 (19.37)

Shock absorber
Compression mm(in) 329.5 (12.97)

Expansion N(kfg) 750 ± 120 (75 ± 12)

Damping force (0.3m/s)
Compression N(kfg) 370 ± 80 (37 ± 8)

Free height mm(in) 354.2 (13.94)

1.6 GSL MT
I.D color GREEN - WHITE
Spring
Free height mm(in) 359.9 (14.16)
1.6 GSL AT
I.D color GREEN - YELLOW

REAR SUSPENSION SYSTEM

Items Specifications

Type Torsion beam axle

Type Gas

Stroke mm(in) 213 (8.38)

Expansion mm(in) 606 ± 3 (23.85 ± 0.11)

Shock absorber 393 + 3, -free (15.47 +
Compression mm(in)
0.11, -free)

Expansion N(kfg) 610 ± 100 (61 ± 10)

Damping force (0.3m/s)
Compression N(kfg) 330 ± 70 (33 ± 7)

Free height mm(in) 338.4 (13.32)

Spring
I.D color WHITE - WHITE

WHEELS AND TIRES

Items Specifications
 195/55 R15

Tire size 185/65 R14

175/70 R14

5.5J X 14 offset = 46
Steel
5J X 14 offset = 39

Wheel size 5.5J X 15 offset = 46

Aluminium
5.5J X 14 offset = 46

PCD (mm) 100

Tire pressure kPa(kg/cm², psi) Gasoline 210 (2.1, 30)

WHEEL ALIGNMENT
Front
Items Rear
Power Steering Manual Steering

Camber 0° ± 0.5° -1° ± 0.5°

to ground 4° ± 0.5° -
Caster
to body 4.5° 4.07° -

Toe-in (Total/Individual) -0.2°~0.2°/ -0.1°~0.1° 0.2°~0.6°/ 0.1°~0.3

King pin angle 13° ± 0.5° -

185, 195 Tire 1470 (57.87) - 1460 (57.48)

Tread mm(in)
175 Tire 1484 (58.42) 1484 (58.42) 1474 (58.03)

TIGHTENING TORQUE

Items Nm Kgf·m lb-ft

Wheel nut 90 ~ 110 9 ~ 11 65 ~ 79

Driveshaft nut 200 ~ 260 20 ~ 26 144 ~ 188

Front strut upper mounting nut 20 ~ 30 2~3 14.4 ~ 21.6

Front strut lower mounting nut 100 ~ 120 10 ~ 12 72 ~ 86

Front strut mounting self-locking nut 50 ~ 70 5~7 36 ~ 50

Subframe mounting bolt 95 ~ 120 9.5 ~ 12 68 ~ 86

Wheel speed sensor mouning bolt 13 ~ 17 1.3 ~ 1.7 9.4 ~ 12

Front lower arm ball joint mounting bolt 100 ~ 120 10 ~ 12 72 ~ 86

Front lower arm bush(A) mounting bolt 100 ~ 120 10 ~ 12 72 ~ 86

Front lower arm bush(G) mounting bolt 120 ~ 140 12 ~ 14 86 ~ 101

Engine mounting bolt 50 ~ 65 5 ~ 6.5 36 ~ 47

Stabilizer bracket mounting bolt 45 ~ 55 4.5 ~ 5.5 32 ~ 39

Tie rod end ball joint self-locking nut 16 ~ 34 1.6 ~ 3.4 11 ~ 24

Tie rod toe adjustment nut 50 ~ 55 5 ~ 5.5 36 ~ 39

Stabilizer bar link mounting nut 35 ~ 45 3.5 ~ 4.5 25 ~ 32

Rear shock absorber upper mounting nut 40 ~ 60 4~6 28 ~ 43

Rear shock absorber lower mounting nut 100 ~ 120 10 ~ 12 72 ~ 86

Rear torsion alxe beam mounting bolt 100 ~ 120 10 ~ 12 72 ~ 86

Rear shock absorber self-locking nut 22 ~ 32 2.2 ~ 3.2 15 ~ 23

Rear brake caliper to knuckle bolt 65 ~ 75 6.5 ~ 7.5 47 ~ 54

Rear hub unit bearing 50 ~ 60 5~6 36 ~ 43

Brake hose mounting bolt 9 ~ 14 0.9 ~ 1.4 6 ~ 10

Wheel speed sensor wire mounting bolt 7 ~ 11 0.7 ~ 1.1 5~7

Replace the self-locking nuts with new ones after removal.

LUBRICANTS
Item The recommended Quantity

Ball : CGMS01 (CMS-H006) 0.5g ~ 1g

Lower arm ball joint
Dust cober : CGMS03 (CMS-H006) 4g ~ 5g

Strut insulator bearing GLE 3.9g ± 1g

Ball : LUBCHEM 0.2g ~ 1.7g

Stabilizer bar link ball joint
Dust cover : LUBCHEM 1.2g ~ 1.7g

Suspension System > General Information > Special Service Tools

SPECIAL TOOLS

Tool(Number and Name) Illustration Use

09216-21100 Removal & installation of lower arm
Mount bushing remover and bushing(G)
installer

09214-32000 Removal & installation of lower arm

Mount bushing remover and bushing(G)
installer

09568-4A000 Removal of the front lower arm and tie

Ball joint remover rod end ball joint

09546-26000 Compression of the coil spring

Strut spring compressor

Suspension System > General Information > Troubleshooting

TROUBLESHOOTING

Vehicle inspection
SYMPTOM CHART
Symptom Suspect Area Remedy (See page)

Squeak or grunt-noise from the Front stabilizer bar Under these conditions, the
front suspension, occurs more in noise is acceptable.
cold ambient temperatures-more
noticeable over rough roads or
when turning

Clunk-noise from the front Loose front struts or shocks Inspect for loose nuts or bolts.
suspension, occurs in and out of Tighten to specifications.
turns See page SS-25.

Clunk-noise from the rear Loose rear suspension Inspect for loose or damaged
suspension, occurs when shifting components rear suspension components.
from reverse to drive Repair or install new
components as necessary.
See page SS-42.

Click or pop-noise from the front Worn or damaged ball joints Install new lower arm as
suspension-more noticeable over necessary.
rough roads or over bumps See page SS-33.

Worn or damaged ball joints Install new lower arm as

Click or pop-noise occurs when
necessary.
vehicle is turning
See page SS-33.
 Damaged or worn Birfield joint Repair or install a new Birfied
Click or snap-occurs when
joint as necessary.
accelerating around a corner
See DS group - driveshaft.

Front suspension noise-a Steering components Go to detailed test A.

squeak, creak or rattle noise- Loose or bent front struts or See page SS-10.
occurs mostly over bumps or shock absorbers
rough roads Damaged spring or spring
mounts
Damaged or worn arm bushings
Worn or damaged stabilizer bar
bushing or links

Uneven seating surface between Repair or install a new parts as

Groaning or grinding-noise from
the insulator and panel by the necessary.
the front strut, occurs when
burrs around the strut insulator See page SS-29.
driving on bumpy roads or
mounting bolts and the insulator
turning the vehicle
boltes mounting holes

Rear suspension noise - a Loose or bent rear shock Go to detailed test B.

squeak, creak or rattle noise - absorbers See page SS-11.
occurs mostly over bumps or Damaged spring or spring
rough roads mounts
Damaged or worn control arm
bushings

Shudder-occurs during Rear axle assembly Check the axle mounts and Rear
acceleration from a slow speed mispositioned suspension the rear suspension
or stop Damaged or worn front for damage or wear. Repair as
suspension components necessary.
Check for a loose stabilizer bar,
damaged or loose strut/strut
bushings or loose or worn ball
joints. Inspect the steering
linkage for wear or damage.
Repair or Install new
components as necessary.

Excessive positive caster Check the caster alignment

Shimmy-most noticeable on
angle.
coast/deceleration-also hard
Correct as necessary.
steering condition
See page SS-51.

Tire noise-hum/moan at constant Abnormal wear patterns Spin the tire and Check for tire
speeds wear. Install a new tire as
necessary. Inspect for
damaged/worn suspension
components. Carry out wheel
alignment.
See page SS-50, SS-51.

Tire noise-noise tone lowers as Out-of-balance tire Balance the tire and road test.
the vehicle speed is lowered Install a new tire as necessary.
See page SS-51.
 Nail puncture or stone in tire Inspect the tire. Repair as
Tire noise - ticking noise, change
tread necessary.
with speed
See page SS-51.

Wheel and tire-vibration and Damaged or worn tire Go to detailed test C.

noise concern is directly related See page SS-12.
to vehicle speed and is not
affected by acceleration,
coasting or decelerating

Tire wobble or shudder - occurs Damaged wheel bearings Spin the tire and check for
at lower speeds abnormal wheel bearing play or
roughness. Adjust or Install new
wheel bearings as necessary.
See DS group - front/rear axle.

Damaged wheel Inspect the wheel for damage.

Install a new wheel as
necessary.
See page SS-53.

Damaged or worn suspension Inspect the suspension

components components for wear or damage.
Repair as necessary.
See page SS-46.

Loosen wheel nuts Check the wheel nuts.

Tighten to specification.
See page SS-53.

Damaged or uneven tire wear Spin the tire and Check for
abnormal tire wear or damage.
Install a new tire as necessary.
See page SS-51.

Tire shimmy or shake - occurs at Wheel/tire out of balance See page SS-50.
lower speeds
Uneven tire wear Check for abnormal tire wear.
Install a new tire as necessary.
See page SS-51.

Excessive radial runout of wheel Carry out a radial runout test of

or tire the wheel and tire.
Install a new tire as necessary.
See page SS-53.

Worn or damaged wheel studs or Inspect the wheel studs and

elongate stud holes wheels.
Install new components as
necessary.
See page SS-53.

Excessive lateral runout of the Carry out a lateral runout test of

wheel or tire the wheel and tire.
Check the wheel, tire and hub.
 Repair or Install new
components as necessary.
See page SS-53.

Clean the mounting surfaces of

Foreign materal between the
the brake disc and hub.
brake disc and hub.
See DS group - front/rear axle.

High speed shake or shimmy- Excessive wheel hub runout Go to detailed test D.
occurs at high speeds Damaged or worn tires See page SS-15.
Damaged or worn wheel
bearings
Worn or damaged suspension or
steering linkage
Brake disc or drum imbalance

Drift left or right Tires Go to detailed test E.

Steering linkage See page SS-17.
Alignment
Base brake system

Steering wheel Alignment Go to detailed test F.

Steering linkage See page SS-18.
Front lower arm ball joint

Tracks incorrectly Rear suspension Go to detailed test G.

Caster See page SS-19.

Rough ride Front strut and spring assembly Go to detailed test H.

Rear shock absor and spring See page SS-20.
assembly

Excessive noise Front or rear stabilizer bar Go to detailed test I.

components See page SS-20.
Springs
Suspension components
Shock absorbers

Incorrect tire wear Tire or unbalanced wheels Go to detailed test J.

Tire inflation See page SS-21.
Strut
Alignment

Vibration Wheel/tire Go to detailed test K.

Front wheel drivshaft(s) See page SS-22.
Steering system
Strut and spring assembly
Spring and strut mounting
Front lower arm ball joint
Front lower arm mounting bolt
bushing
Stabilizer bar bushings
Wheel hubs and bearing
Rear suspension arms and
bushings
 Inflate tires to specification.
See page SS-51.
Tire/wheel
Redistribute the load as
Vehicle load
necessary.
Vehicle leans Suspension components
Visually inspect the suspention
system.
Incorrect ride height
Correct the ride height as
necessary.

Poor returnability High knuckle rotating torque Go to detailed test E.

Alignment See page SS-17.

DETAILED TEST A : FRONT SUSPENSION NOISE

CONDITIONS DETAILS/RESULTS/ACTIONS

ROAD TEST THE VEHICLE

1. Test drive the vehicle.
2. During the road test, drive the vehicle over a rough road.
Determine from which area/component the noise is
originating.
● Is there a squeak, creak or rattle noise ?
→ YES
Go to
→ NO
The suspension system is OK. Conduct a diagnosis on other
suspect systems.

INSPECT THE STEERING SYSTEM

1. Check the steering system for wear or damage.
Carry out a steering linkage test.
Inspect the tire wear pattern. See page SS-24.
● Are the steering components worn or damaged ?
→ YES
Repair the steering system. Install new components as
necessary. Test the system for normal operation.
→ NO
Go to

FRONT SHOCK ABSORBER/STRUT CHECK

1. Check the front shock absorbers/strut mounts for loose bolts
or nuts.
2. Check the front shock absorbers/struts for damage. Carry out
a shock absorber check.
● Are the front shock absorbers/struts loose or damaged ?
→ YES
Tighten to specifications if loose.
Install new front shock absorbers/struts if damaged. Test the
system for normal operation.
→ NO
Go to
CHECK THE FRONT SPRINGS

Check the front spring and front spring mounts/brackets for wear
or damage

● Are the front springs or spring mounts/brackets worn or

damaged ?

→ YES
Repair or Install new components as necessary. Test the system
for normal operation.

→ NO
Go toA5.

CHECK THE STABILIZER BAR

1. Check the stabilizer bar bushing and links for damage or
wear.
2. Check the stabilizer bar for damage.
3. Check for loose or damaged stabilizer brackets.
● Are the stabilizer bar/track bar components loose, worn or
damaged ?
→ YES
Repair or Install new components as necessary. Test the
system for normal operation.
→ NO
Suspension system is OK. Conduct diagnosis on other
suspect systems.

DETAILED TEST B : REAR SUSPENSION NOISE

CONDITIONS DETAILS/RESULTS/ACTIONS

ROAD TEST THE VEHICLE

1. Test drive the vehicle.
2. During the road test, drive the vehicle over a rough road.
Determine from which area/component the noise is
originating.
● Is there a squeak, creak or rattle noise ?
→ YES
Go to
→ NO
The suspension system is OK. Conduct a diagnosis on other
suspect systems.

REAR SHOCK ABSORBER/STRUT CHECK

1. Raise and support the vehicle. See GI group - lift support
point.
2. Check the rear shock absorber/strut mounts for loose bolts or
nuts.
3. Check the rear shock absorbers/strut for damage. Carry out a
 shock absorber check.
● Are the rear shock absorbers/struts loose or damaged ?
→ YES
Tighten to specifications if loose.
Install new rear shock absorbers/struts if damaged. Test the
system for normal operation.
→ NO
Go to

CHECK THE REAR SPRINGS

Check the rear springs and rear spring mounts/brackets for wear
or damage.

● Are the rear springs or spring mounts/brackets worn or

damaged ?

→ YES
Repair or Install new components as necessary. Test the system
for normal operation.

→ NO
Go toB4.

CHECK THE TRAILING ARMS

1. Inspect the trailing arm bushings for wear or damage. Check
for loose trailing arm bolts.
2. Inspect for twisted or bent trailing arms.
● Are the trailing arms loose, damaged or worn ?
→ YES
Repair or Install new components as necessary. Test the
system for normal operation.
→ NO
Suspension system is OK. Conduct diagnosis on other
suspect systems.

DETAILED TEST C : WHEEL AND TIRE

CONDITIONS DETAILS/RESULTS/ACTIONS

ROAD TEST THE VEHICLE

Wheel or tire vibrations felt in the steering wheel are most

likely related to the front wheel or tire. Vibration felt through the
seat are most likely related to the rear wheel or tire. This may
not always be true, but it can help to isolate the problem to the
front or rear of the vehicle.
Test drive the vehicle at different speed ranges.

During the road test, if the vibration can be eliminated by placing

 the vehicle in neutral or is affected by the speed of the engine,
the cause is not the wheels or tires.

● Is there a vibration and noise ?

→ YES
Go toC2.

→ NO
The wheel and tires are OK. Conduct a diagnosis on other
suspect systems.

CHECK THE FRONT WHEEL BEARINGS

Check the front wheel bearings.

Refer to Wheel Bearing Check (See DS group - front axle).

● Are the wheel bearing OK ?

→ YES
Go toC3.

→ NO
Inspect the wheel bearings. Adjust or Repair as necessary. Test
the system for normal operation.

INSPECT THE TIRES

1. Check the tires for missing weights.
2. Check the wheels for damage.
3. Inspect the tire wear pattern. See page SS-24.
● Do the tires have an abnormal wear pattern ?
→ YES
Correct the condition that caused the abnormal wear. Install
new tire(s).
Test the system for normal operation.
→ NO
Go to

TIRE ROTATION DIAGNOSIS

1. Spin the tires slowly and watch for signs of lateral runout.
2. Spin the tires slowly and watch for signs of radial runout.
● Are there signs of visual runout ?
→ YES
Go to
→ NO
Check the wheel and tire balance.
Correct as necessary. Test the system for normal operation.

RADIAL RUNOUT CHECK ON THE TIRE

Measure the radial runout of the wheel and tire assembly. A

typical specification for total radial runout is 1.15mm (0.059 inch).
 ● Is the radial runout within specifications ?

→ YES
Go toC8.

→ NO
Go toC6.

RADIAL RUNOUT CHECK ON THE WHEEL

Measure the radial runout of the wheel. A typical specification for

total radial runout is 1.14mm (0.045 inch).

● Is the radial runout within specifications ?

→ YES
Install a new tire. Test the system for normal operation.

→ NO
Go toC7.

CHECK THE HUB/BRAKE DISC OR DRUM PILOT RUNOUT OR BOLT CIRCLE RUNOUT

Measure the pilot or bolt circle runout. A typical specification for

radial runout is :
● pilot runout - less than 0.15mm (0.006 inch).
● bolt circle runout - less than 0.38 mm (0.015 inch).

● Is the radial runout within specification ?

→ YES
Install a new wheel. Test the system for normal operation.

→ NO
Repair or Install new components as necessary. See page SS-28
for the front suspension or SS-42 for the rear suspension.

LATERAL RUNOUT CHECK ON THE TIRE

Measure the lateral runout of the wheel and tire assembly. A

typical specification for total lateral runout is 2.5mm (0.098 inch).

● Is the lateral runout within specifications ?

→ YES
Wheel and tires are OK. Conduct diagnosis on other suspect
systems.

→ NO
Go toC9.

LATERAL RUNOUT CHECK ON THE WHEEL

Measure the lateral runout of the wheel. A typical specification for

total radial runout is 1.2mm (0.047 inch).
 ● Is the lateral runout within specifications ?

→ YES
Install a new tire. Test the system for normal operation.

→ NO
Go toC10.

CHECK THE FLANGE FACE LATERAL RUNOUT

Measure the flange face lateral runout. A typical specification for

lateral runout is :
● hub/brake disc - less than 0.13mm (0.005 inch).

● Is the lateral runout within specifications ?

→ YES
Install a new wheel. Test the system for normal operation.

→ NO
Repair or Install new components as necessary. See page SS-27
for the front suspension or SS-42 for the rear suspension.

DETAILED TEST D :
CONDITIONS DETAILS/RESULTS/ACTIONS

CHECK FOR FRONT WHEEL BEARING ROUGHNESS

1. Raise and support the front end of the vehicle so that the front
wheel and tire assemblies can spin.
See GI group - lift support point.
2. Spin the front tires by hand.
● Do the wheel bearings feel rough ?
→ YES
Inspect the wheel bearings. Repair as necessary. Test the
system for normal operation.
→ NO
Go to

CHECK THE END PLAY OF THE FRONT WHEEL BEARINGS

Check the end play of the front wheel bearings.

● Is the end play OK ?

→ YES
Go toD3.

→ NO
Adjust or Repair as necessary. Test the system for normal
operation.
MEASURE THE LATERAL RUNOUT AND THE RADIAL RUNOUT OF THE FRONT WHEELS ON
THE VEHICLE

Measure the lateral runout and the radial runout of the front
wheels on the vehicle. Go to detailed test C.

● Are the measurements within specifications ?

→ YES
Go toD4.

→ NO
Install new wheels as necessary and Balance the assembly. Test
the system for normal operation.

MEASURE THE LATERAL RUNOUT OF THE FRONT TIRES ON THE VEHICLE

Measure the lateral runout of the front tires on the vehicle. Go to

detailed test C.

● Is the runout within specifications ?

→ YES
Go toD5.

→ NO
Install new tires as necessary and Balance the assembly. Test
the system for normal operation.

MEASURE THE RADIAL RUNOUT OF THE FRONT TIRES ON THE VEHICLE

Measure the radial runout of the front tires on the vehicle. Go to

detailed test C.

● Is the runout within specifications ?

→ YES
Balance the front wheel and tire assemblies. If any tire cannot be
balanced, Install a new tire. Test the system for normal operation.

→ NO
Go toD6.

MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY

Mark the high runout location on the tire and also on the wheel.
Break the assembly down and rotate the tire 180 degrees
(halfway around) on the wheel. Inflate the tire and measure the
radial runout.

● Is the runout within specifications ?

→ YES
Balance the assembly. Test the system for normal operation.
 → NO
If the high spot is not within 101.6mm (4 inches) of the first high
spot on the tire, Go toD7.

MEASURE THE WHEEL FLANGE RUNOUT

Dismount the tire and mount the wheel on a wheel balancer.

Measure the runout on both wheel flanges. Go to detailed test C

● Is the runout within specifications ?

→ YES
Locate and Mark the low spot on the wheel. Install the tire,
matching the high spot on the tire with the low spot on the wheel.
Balance the assembly. Test the system for normal operation. If
the condition persists, Go toD8.

→ NO
Install a new wheel. Check the runout on the new wheel. If the
new wheel is within limits, locate and Mark the low spot. Install
the tire, matching the high spot on the tire with the low spot on the
wheel. Balance the assembly. Test the system for normal
operation. If the condition persists, Go toD8.

CHECK FOR VIBRATION FROM THE FRONT OF THE VEHICLE

Spin the front wheel and tire assemblies with a wheel balancer
while the vehicle is raised on a hoist. Feel for vibration in the front
fender or while seated in the vehicle.

● Is the vibration persent ?

→ YES
Substitute known good wheel and tire assemblies as necessary.
Test the system for normal operation.

→ NO
Check the driveline components. Test the system for normal
operation.

DETAILED TEST E : DRIFT LEFT OR RIGHT

CONDITIONS DETAILS/RESULTS/ACTIONS

CHECK THE TIRES

Inspect the tires for excessive wear or damage.

● Are the tires excessively worn or damaged ?

→ YES
Install new tires.
 → NO
Go toE2.

CHECK THE STEERING LINKAGE

1. Raise and support the vehicle.
2. Check the steering components for indications of excessive
wear or damage.
See ST group - specification.
● Is there an indication of excessive wear or damage ?
→ YES
Repair or Install new components as necessary.
→ NO
Go to

CHECK THE VEHICLE ALIGNMENT

1. Place the vehicle on an alignment rack.
Check the vehicle alignmnt.
● Is the alignment within specification ?
→ YES
Go to
→ NO
Adjust the alignment as necessary.
See page SS-50 (wheel alignment).

BRAKE DRAG DIAGNOSIS

Apply the brakes while driving.

● Does drift or pull occur when the brakes are applied ?

→ YES
See BR group - specification.

→ NO
If the steering wheel is in the center, the vehicle is OK.

If the steering wheel is off-center, Go to Detailed TestF.

DETAILED TEST F : STEERING WHEEL OFF-CENTER

CONDITIONS DETAILS/RESULTS/ACTIONS

CHECK THE CLEAR VISION

Place the vehicle on an alignment rack.

● Is the clear vision within specification ?

→ YES
Go toF2.

→ NO
Adjust the clear vision to specification.
INSPECT THE STEERING COMPONENTS
1. Raise and support the vehicle.
2. Inspect the steering components for excessive wear or
damage.
See ST group - specification.
● Are the steering components excessively worn or
damaged ?
→ YES
Repair or Install new components as necessary.
→ NO
If it tracks corectly, vehicle is OK.
If it tracks incorrectly, Go to Detailed Test

DETAILED TEST G : TRACKS INCORRECTLY

CONDITIONS DETAILS/RESULTS/ACTIONS

CHECK THE CASTER

Place the vehicle on an alignment rack.

● Are the caster within specification ?

→ YES
Go toG2.

→NO
Replace bent or damaged parts.

CHECK THE REAR SUSPENSION

1. Measure the vehicle wheel base for LH and RH.
2. Compare the measurements.
● Are the measurements the same ?
→ YES
If the ride is smooth, vehicle is OK.
If the ride is rough, Go to Detailed Test
→ NO
Inspect the rear suspension components for wear or damage.
Repair or Install new components as necessary.
See page SS-42 (rear suspension).

DETAILED TEST H : ROUGH RIDE

CONDITIONS DETAILS/RESULTS/ACTIONS

CHECK THE FRONT SHOCK ABSORBER

1. Raise support the vehicle.
2. Inspect the front shock absorber for oil leaks or damage.
● Are the tires excessively worn or damaged ?
→ YES
Install new front shock absorbers.
See page SS-29 (front strut assembly).
 → NO
Go to

CHECK THE REAR SHOCK ABSORBERS

Inspect the rear shock absorbers for oil leaks or damage.

● Are the rear shock absorbers leaking ?

→ YES
Install new rear shock absorbers.
See page SS-43 (rear strut assembly).

→ NO
The vehicle is OK. Go toTROUBLESHOOTING.

DETAILED TEST I : EXCESSIVE NOISE

CONDITIONS DETAILS/RESULTS/ACTIONS

INSPECT THE SUSPENSION

1. Raise and support the vehicle.
2. Inspect the shock absorber mounting bolts.
● Are the mounting bolts loose or broken ?
→ YES
Tighten or Install new shock absorber mounting bolts.
See page SS-29 and SS-46 (front/rear suspension)
→ NO
Go to

INSPECT THE SPRING AND TORSION BARS

Inspect the springs and stabilizer bars for damage.

● Are the spring or stabilizer bars damaged ?

→ YES
Install new spring and/or stabilizer bars.
See page SS-36 (front stabilizer bars).

→ NO
Go toI3.

INSPECT THE FRONT SUSPENSION

Inspect the front suspension components for excessive wear or

damage.

● Are the front suspension components worn or damaged ?

→ YES
Install new front suspension components.
See page SS-25 (front suspension).
 → NO
The vehicle is OK. Go toTROUBLESHOOTING.

DETAILED TEST J : INCORRECT TIRE WEAR

CONDITIONS DETAILS/RESULTS/ACTIONS

INSPECT THE TIRES

1. Raise and support the vehicle.
2. Inspect the tires for uneven wear on the inner or outer
shoulder.
● Is there uneven tire wear ?
→ YES
Align the vehicle. Install new tires if badly worn.
→ NO
Go to

UNEVEN TIRE WEAR

Inspect the tires for a feathering pattern.

● Do the tires have a feahering pattern ?

→ YES
Align the vehicle. Install new tires if badly worn.

→ NO
Go toJ3.

CHECK FOR CUPPED TIRE

Inspect the tires for cupping or dishing.

● Are the tires cupped or dished ?

→ YES
Balance and Rotate the tires.

→ NO
The vehicle is OK. Go toTROUBLESHOOTING.

DETAILED TEST K : VIBRATION

CONDITIONS DETAILS/RESULTS/ACTIONS

ROAD TEST

Accelerate the vehicle to the speed at which the customer

indicated the vibration occured.

● Is the vibration present ?

→ YES
Go toK2.
 → NO
The vehicle is OK. Go toTROUBLESHOOTING.

INSPECT THE TIRES

1. Raise and support the vehicle with a frame contact hoist.
2. Inspect the tires for extreme wear or damage, cupping, or flat
spots.
● Are the tires OK ?
→ YES
Go to
→ NO
Check the suspension components for misalignment,
abnormal wear, or damage that may have contributed to the
tire wear.
Correct the suspension concerns and Install new tires.

INSPECT THE WHEEL BEARINGS

Spin the tires by hand to check for wheel bearing rougness.

● Is the front wheel bearing OK ?

→ YES
Go toK4.

→ NO
Install new front wheel bearings as necessary.
See Ds group - front axle.

TIRE/WHEEL BALANCE

Check the tire/wheel balance.

● Are the tires balanced ?

→ YES
Go toK5.

→ NO
Balance the tires and wheels as necessary.

MEASURE THE RUNOUTS

For each wheel position measure, locate and mark the following
items.
See page SS-53 (wheel/tire).
- High point of the tire/wheel assembly total radial runout
- High point of the wheel radial runout
- High point of the wheel lateral runout

● Are the runouts as specified ?

→ YES
 Go toK7.

→ NO
Go toK6.

SUBSTITUTE THE WHEELS AND TIRE

1. Substitute a known good set of wheels and tires.
2. Carry out a road test.
3. If the vehicle still exhibits a shake or vibration, note the vehicle
speed and/or engine rpm which it occurs.
● Is the vibration felt ?
→ YES
Engine/transmission imbalance.
See the specification of TR group, EM group, FL group and
EC group.
→ NO
Install the original tire/wheel assemblies one by one, Road
testing at each step until the damaged tire(s)/wheel(s) as
necessary. Test the system for normal operation.

Wheel /tire noise, vibration and harshness concerns are directly related to vehicle speed and are not
generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can
vibrate at more than one speed. A vibration that is affected by the engine rpm, or is eliminated by
placing the transmission in Neutral is not related to the tire and wheel. As a general rule, tire and
wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies.
Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially
isolate a concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can be caused
by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel
assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear
chart to determine the tire wear conditions and actions
WHEEL AND TIRE DIAGNOSIS

Rapid wear at the center Rapid wear at both shoulders Wear at one shoulder

• Center-tread down to fabric • Under-inflated tires • Toe adjustment out of

due to excessive over inflated • Worn suspension specification
tires components • Camber out of specification
• Lack of rotation • Excessive cornering speeds • Damaged strut
• Excessive toe on drive • Lack of rotation • Damaged lower arm
wheels
• Heavy acceleration on drive
Partial wear Feathered edge Wear pattern
 • Caused by irregular burrs on • Toe adjustment out of • Excessive toe on non-drive
brake drums specification wheels
• Damaged or worn tie rods • Lack of rotation
• Damaged knuckle

Suspension System > Front Suspension System > Components and

Components Location

COMPONENTS
Suspension System > Front Suspension System > Front Strut Assembly >
Components and Components Location
COMPONENTS

Suspension System > Front Suspension System > Front Strut Assembly >
Repair procedures
REMOVAL
1. Loosen the wheel nuts slightly.
Raise the front of the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire(A) from front hub(B).

Be careful not to damage the hub bolts(C) then remove the front wheel and tire(A).

3. Remove the brake hose bracket(B) and speed sensor wire mounting bolt(C) from the strut
assembly(A).

4. Remove the speed sensor wire mounting bolt(B) and speed sensor(A).

5. Remove the nut(B) from the stabilizer bar link(A).

6. Remove the strut upper mounting nuts(A).

7. Remove the strut lower mounting bolts(A) and then remove the strut assembly(B).

INSTALLATION
1 Install the strut assembly(B) and then install the strut lower mounting bolts(A).
.
Tightening torque :
100 ~ 120 Nm (10 ~ 12 Kgf·m, 72 ~ 86 lb-ft)
2 Install the strut upper mounting nuts(A).
.
Tightening torque :
20 ~ 30 Nm (2 ~ 3 Kgf·m, 14.4 ~ 21.6 lb-ft)

When installing the strut assembly mounting nuts, check if the self-locking nut is in the right
direction as shown in the illustration.

Power steering

Manual steering
3 Install the nut(B) on the stabilizer bar link(A).
.
Tightening torque :
35 ~ 45 Nm (3.5 ~4.5 Kgf·m, 25 ~ 32 lb-ft)

4 Install the speed sensor wire mounting bolt(B) and speed sensor(A).
.
Tightening torque :
A : 13 ~ 17 Nm (1.3 ~ 1.7 Kgf·m, 9.4 ~ 12 lb-ft)
B : 7 ~ 11 Nm (0.7 ~ 1.1 Kgf·m, 5 ~ 7 lb-ft)
5 Install the brake hose bracket(B) and speed sensor wire mounting bolt(C) on the strut assembly(A).
.
Tightening torque :
Brake hose mounting bolt ;
9 ~14 Nm (0.9 ~ 1.4 Kgf·m, 6 ~ 10 lb-ft)

6 Install the front wheel and tire(A) on the front hub(B).

.
Tightening torque :
90 ~ 110 Nm (9 ~ 11 Kgf·m, 65 ~ 79 lb-ft)

Be careful not to damage the hub bolts(C) then install the front wheel and tire(A).
DISASSEMBLY
1. Using the special tool (09546-26000), compress the coil spring(A) until there is only a little tension
of the spring on the strut.

2. Remove the self-locking nut(C) from the strut assembly(B).

3. Remove the insulator, spring seat, coil spring and dust cover from the strut assembly.

INSPECTION
1. Check the strut insulator bearing for wear or damage.
2. Check rubber parts for damage or deterioration.
3. Compress and extend the piston rod(A) and check that there is no abnormal resistance or unusual
sound during operation.

REASSEMBLY
1. Install the spring lower pad(D) so that the protrusions(A) fit in the holes(C) in the spring lower
seat(B).
2. Compress coil spring using special tool (09546-26000).
Install compressed coil spring into shock absorber.

1) Indicated two identification color marks on the coil spring one follows model option (see
page SS-2) the other follows load classification according to the below.
Pay attention to distiuguish between the two marks and then install them.
2) Install the coil spring wth the idemtification mark directed toward the knuckle.

3. After fully extending the piston rod, install the spring upper seat and insulator assembly.
4. After seating the upper and lower ends of the coil spring(A) in the upper and lower spring seat
grooves(B) correctly, tighten new self-locking nut temporarily.

5. Remove the special tool(09546-26000).

6 Tighten the self-locking nut to the specified torque.
.
Tightening torque :
50 ~ 70 Nm (5 ~7 kgf·m, 36 ~ 50 lb-ft)

INSPECTION
1. Check the strut insulator bearing for wear or damage.
2. Check rubber parts for damage or deterioration.
3. Compress and extend the piston rod(A) and check that there is no abnormal resistance or unusual
sound during operation.
Suspension System > Front Suspension System > Front Lower Arm >
Components and Components Location

COMPONENTS
Suspension System > Front Suspension System > Front Lower Arm > Repair
procedures

REMOVAL
1. Loosen the wheel nuts slightly.
 Raise the front of the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire(A) from front hub(B).

Be careful not to damage the hub bolts(C) then remove the front wheel and tire(A).

3. Remove the lower arm ball joint mounting bolts(A).

4. Remove the lower arm mounting bolts(A).

REPLACEMENT
1. Using the special tools(09214-32000 & 09216-211000), remove the bushing from the lower arm.

2. Apply soap solution to the following parts.

A. Outer surface of the bushing.
B. Inner surface of the lower bushing mounting part.
3 Using the special tools(09214-32000 & 09216-21100), install the busing on the lower arm.
.

Insert bushing in the direction shown on the arrow.

Separation force is over 800Kg

INSTALLATION
1 Install the lower arm mounting bolts(A).
.
Tightening torque :
A bushing :
100 ~ 120 Nm (10 ~ 12 Kgf·m, 72 ~ 86 lb-ft)
G bushing :
100~140 Nm (10 ~ 14 Kgf·m, 72 ~ 101 lb-ft)

2 Install the lower arm ball joint mounting bolts(A).

.
Tightening torque :
100 ~ 120 Nm (10 ~ 12 Kgf·m, 72 ~ 86 lb-ft)
3 Install the front wheel and tire(A) on the front hub(B).
.
Tightening torque :
90 ~ 110 Nm (9 ~ 11 Kgf·m, 65 ~ 79 lb-ft)

Be careful not to damage the hub bolts(C) then install the front wheel and tire(A).

Suspension System > Front Suspension System > Front Stabilizer Bar >
Components and Components Location

COMPONENTS
Suspension System > Front Suspension System > Front Stabilizer Bar > Repair
procedures
REMOVAL
1. Loosen the wheel nuts slightly.
Raise the front of the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire(A) from front hub(B).

Be careful not to damage the hub bolts(C) then remove the front wheel and tire(A).

3. Remove the stabilizer bar link(B) from the strut assmembly(A).

4. Remove the tie rod end(A) from the knuckle by using the special tool(09568-4A000).

5. Remove the two bolts(A) for lower arm ball joint.

6. Drain power steering oil.
7. Remove the pressure pipe mounting bolt(A).

8. Disconnect between the return hose and tube(A).

9. Remove two engline mounting bolts(A,B) and six subframe mounting bolts in order to remove the
subframe.
10. Remove both stabilizer brackets(A) and two bushes respcetively.

11. Remove the stabilizer bar.

 Be careful not to do damage to pressure tubes.

INSTALLATION
1. Install the bushing(B) on the stabilizer bar(A).

Bring clamp(C) of stabilizer bar(A) into contact with bushing(B).

2. Install the bracket on the bushing(B).

3 After tightening the bolts of the bushing bracket temporarily, install the bushing bracket on the
. opposite side.

Tightening torque :
45 ~ 55 Nm (4.5 ~ 5.5 Kgf·m, 32 ~ 39 lb-ft)

4 Install the six subframe mounting bolts, then the two engine mounting bolts(A,B).
.
Tightening torque :
Engine mounting ;
50 ~ 65 Nm (5 ~ 6.5 Kgf·m, 36 ~ 47 lb-ft)
Subframe mounting ;
95 ~ 120 Nm (9.5 ~ 12 Kgf·m, 68 ~ 86 lb-ft)
5 Install the pressure pipe mounting bolt(A).
.
Tightening torque :
55 ~ 65 Nm (5.5 ~ 6.5 Kgf·m, 39 ~ 47 lb-ft)
6. Connect between the return tube and hose(A).

Be sure to connect between a tube and a hose as shown in the illustration.

7 Install the two bolts(A) for the lower arm ball joint.
.
Tightening torque :
100 ~ 120 Nm (10 ~ 12 Kgf·m, 72 ~ 86 lb-ft)

8 Install the nut(B) on the stabilizer bar link(A).

.
Tightening torque :
35 ~ 45 Nm (3.5 ~ 4.5 Kgf·m, 25 ~ 32 lb-ft)
9. Install the tie rod end on the knuckle.
10 Install the front wheel and tire(A) on thr front hub(B).
.
Tightening torque :
90 ~ 110 Nm (9 ~ 11 Kgf·m, 65 ~ 79 lb-ft)

Be careful not to do damage the hub bolts(C) then install the front wheel and tire(A).

11. Refill the power steering fluid(PSF-3).

After installation, bleed the air in the power steering system. (refer to ST-10)

INSPECTION
1. Check the stabilizer bar for deterioration and damage.
2. Check all bolts for damage and deformation.
3. Check the stabilizer link dust cover for cracks or damage.

Suspension System > Rear Suspension System > Components and

Components Location

COMPONENTS

Suspension System > Rear Suspension System > Rear Shock Absorber >
Components and Components Location
COMPONENTS

Suspension System > Rear Suspension System > Rear Shock Absorber >
Repair procedures

REMOVAL
1. Remove the wheel and tire.

2. After supporting the rear torsion axle beam with a jack, remove the rear shock absorber lower
mounting bolt. Remove the rear shock absorber.

3. Remove the rear shock absorber mounting bolts(A).

INSTALLATION
1 Tighten the rear shock absorber upper mounting bolt to the specified torque as follows.
.
Specified torque :
 40 ~ 60 Nm (4 ~6 kgf·m, 28 ~ 43 lb-ft)

2 After placing a jack at the bottom of the rear torsion axle beam and jacking up the vehicle to the
. proper location, tighten the rear shock absorber lower mounting bolt(A).

Specified torque :
100 ~ 120 Nm (10 ~ 12 kgf·m, 72 ~ 86 lb-ft)

Check that the rear coil spring is located in the proper position.

Suspension System > Rear Suspension System > Rear Coil Spring >
Components and Components Location

COMPONENTS
Suspension System > Rear Suspension System > Rear Coil Spring > Repair
procedures

REMOVAL
1. Remove the wheel and tire.
2. Remove the brake hose bracket(B) and the wheel speed sensor wire bracket(A).

The brake hose should not expand when the rear torsion axle beam is hanged down from the
body.

3. After placing a jack at the bottom of the rear torsion axle beam, remove the rear shock absorber
lower mounting bolt(A).

4. Remove the rear coil spring(A).

INSTALLATION
1. Install the upper and lower pads on the coil spring by aligning the grooves on the pads.

2. Place the coil spring(A) with the pads on the torsion axle beam and support it with a jack.

3 Install the rear shock absorber mounting bolt(A) by lifting the rear torsion axle beam.
.
Tightening torque Nm(kgf·m,lb-ft) :
100 ~ 120 Nm (10 ~12 kgf·m, 72 ~ 86 lb-ft)
4 Install the wheel speed sensor wire bracket bolt(A) and the brake pressure hose bracket bolt(B).
.
Tightening torque Nm(kgf·m,lb-ft) :
Brake pressure hose bracket ;
9 ~ 14 Nm (0.9 ~1.4 kgf·m, 6 ~ 10 lb-ft)
Speed sensor wire bracket ;
7 ~ 11 Nm (0.7 ~1.1 kgf·m, 5 ~ 7 lb-ft)

INSPECTION
1. Check the coil spring for crack and deformation.
2. Check the coil spring pad for damage and deformation.

Suspension System > Rear Suspension System > Rear torsion axle beam >
Components and Components Location

COMPONENTS
Suspension System > Rear Suspension System > Rear torsion axle beam >
Repair procedures

REMOVAL
1. Remove the rear tire and wheel.
2. Remove the wheel speed sensor wire bracket bolt(A) and the brake pressure hose bracket bolt(B).

3. Remove the brake caliper assembly bolt(A) and the brake disk mounting screw(B).

Hang the brake caliper assembly(C) tightly on a proper place with wire.
4. Remove the rear hub bearing assembly bolts(A).

5. Remove the rear hub bearing assembly(A).

6. Remove the parking brake wire(A).

7. Remove the rear shock absorber mounting bolt(A) from the rear torsion axle beam which is
supported by a jack.

8. Release the rear coil spring tension by lowering the jack and remove the rear coil spring.

9. Remove the rear torsion axle beam mounting bolts.

INSTALLATION
1. Installation is reverse of removal.
2. Install the following parts with the specified torque.
Tightening Torque
Items
Nm(kgf·m,lb-ft)

Rear hub unit bearing mounting bolt 50 ~ 60 (5 ~ 6, 36 ~ 43)

 Rear shock absober lower mounting 100 ~ 120 (10 ~ 12, 72 ~ 86)

Rear torsion axle beam mounting bolt 100 ~ 120 (10 ~ 12, 72 ~ 86)

Suspension System > Tires/Wheels > Tire > Repair procedures

TIRE WEAR
1 Measure the tread depth of the tires.
.
Tread depth of tire [Limit] : 1.6 mm (0.06 in)

2. If the remaining tread(A) depth is less than the limit, replace the tire.

When the tread depth of the tires is less than 1.6 mm (0.06 in.), the wear indicators(B) will
appear.

TIRE ROTATION
Rotate the tires in the pattern illustrated.

CHECKING FOR PULL AND WANDER

If the steering pulls to one side, rotate the tires according to the following wheel rotation procedure.
1. Rotate the front right and front left tires, and perform a road test in order to confirm vehicle stability.
2. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test
again.

3. If the steering continues to pull to one side, rotate the front right and left tires again, and perform a
road test.

4. If the steering continues to pull to the opposite side, replace the front wheels with new ones.
Suspension System > Tires/Wheels > Wheel > Repair procedures

FRONT WHEEL ALIGNMENT

TOE

ITEM Description

A-B<0 Positive (+) toe (toe in)

A-B>0 Negative (-) toe (toe out)

Standard value
Toe-in
Total : -0.2°~0.2°
Individual : -0.1°~0.1°

• Toe-in adjustment should be made by turning the right and left tie rods at the same amount.
• When adjusting toe-in, loosen the outer bellows clip to prevent twisting the bellows.
• After the adjustment, tighten the tie rod end lock nuts firmly and reinstall the bellows clip.
• Adjust each toe-in to be the range of ±0.1°.

Tie rod end lock nuts(A) tightening torque :

50 ~ 55 Nm (5 ~ 5.5 Kgf·m, 36 ~ 39 lb-ft)
CAMBER

ITEM Description

A Positive camber angle

B True vertical

C Strut centerline

When the wheel tilts out at the top, then the camber is positive (+).
When the wheel tilts in at the top, then the camber is negative (-).
The stering knuckle which is installed with the strut assembly is pre-set to the specified camber at the
factory and doesn't need to be adjusted.

Camber : 0°±0.5°

CASTER

Caster :
 • The worn loose or damaged parts of the front suspension assembly must be replaced prior to
measuring front wheel alignment.
• Camber and caster are pre-set to the specified value at the factory and don't need to be
adjusted.
• If the camber and caster are not within specifications, replace bent or damaged parts.
• The difference of left and right wheels about the camber and the caster must be within the
range of 0° ± 0.5°.

REAR WHEEL ALIGNMENT

TOE-IN

Standard value
Toe-in
Total : 0.2°~0.6°
Individual : 0.1°~ 0.3°

CAMBER

Standard value
Camber : -1°± 0.5°

WHEEL RUNOUT
1. Jack up the vehicle and support it with jack stands.
2. Measure the wheel runout with a dial indicator as illustrated.
3. Replace the wheel if the wheel runout exceeds the limit.
Limit Radial Axial

Aluminium 0.3(0.012) 0.3(0.012)

Runout mm(in)
Steel 0.9(0.035) 1.4(0.055)
WHEEL NUT TIGHTENING
1 Tightening torque.
.
Tightening torque :
90 ~ 110 Nm (9 ~ 11 Kgf·m, 65 ~ 79 lb-ft)

When using an impact gun, final tightening torque should be checked using a torque wrench.

2. Tightening order.
Check the torque again after tightening the wheel nuts diagonally.