Workshop Manual

2001 - 2006
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DESCRIPTION
The front suspension system consists of the following components.
• Front strut assemblies
• Front lower arm assemblies
• Front stabilizer bar and links
The front strut and spring assemblies can be disassembled to install any of the new individual components. New LH or
RH front strut and spring assemblies can be installed independently.
The front suspension system can also be disassembled in order to install new.
• Front lower arms
• Front lower arm mounting bolt bushings
New front stabilizer bar components can be installed individually.

Email: suzlever@gmail.com

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COMPONENTS

Email: suzlever@gmail.com

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INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the lower arm for bending or breakage.
3. Check the ball joint dust cover for cracks and damage.
4. Check all bolts for damage and deformation.
5. Measure the ball joint rotating torque.

Standard value
2~3.5 Nm (20~35 kgf.cm, 1.4~2.5 lbf.ft)

A.If the rotating torque is exceeds the limit of the standard value, replace the ball joint assembly.
B.Even if the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless
it has drag and excessive play.

Measure torque using the special tool (09532-11600) and torque wrench(C) at the range of 0.5~2 rpm after
moving the ball joint stud(A) 3° several times at room temperature.

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REMOVAL
1. Remove the front wheel and tire.
2. Remove the split pin, the castle nut and the washer.
3. Loosen the lower arm ball joint nut(A), but do not remove it.

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4. Remove the front strut lower mounting bolts(A) from the strut assembly(B).
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5. Push the axle hub(A) outward to install the Special tool (09568-34000) easily.

6. Using the Special Tool (09568 - 34000), disconnect the lower arm ball joint(C) from the lower arm(B).

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7. Remove the stabilizer link nut(A).

8. Temperarily install the strut lower mounting bolt.

9. To the lower arm mounting bolt, remove the passenger seat side cover(A).

It can be easily removed by loosening the mounting bolts(B).

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10. Remove the lower arm mounting bolts(A,B,C).

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11. Remove the lower arm assembly after completely unfastening the nut of lower arm ball joint which was
loosened temporarily in step 3.

INSTALLATION
Installation is the reverse of the removal procedure.

REPLACEMENT
BALL JOINT AND DUST COVER

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1. Using a flat-tipped (-) screwdriver(A), remove the dust cover(C) from the lower arm ball joint(B).
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2. Remove the snap ring(A).

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3. Using a plastic hammer or the Special tool(09545-3A000), separate the ball joint(B) from the lower arm(A).

4. Using the Special tool (09545 - 11000A/B), press-fit the ball joint into the lower arm assembly(A).

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5. Install the snap ring.

6. Using the Special tool (09545 - 21100), install the dust cover.

LOWER ARM BUSHING (G)

1. Install the Special tools (09545 - 02000, 09216 - 21200, 09216 - 21200) on the lower arm.
2. Press out the bushing.

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3. Apply soap solution to the following parts.

A.Outer surface of the bushing.
B.Inner surface of the lower arm bushing mounting part.
4. Install the new bushing on the lower arm using the Special Tools (09216 - 21100, 09624 - 34000).

Press-in the lower arm bushing (G) in the same direction as shown in illustration.

Pull out force for the bushing :

80 N [800 kg(f), 11.9 lb(f)] or more

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Email: suzlever@gmail.com

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COMPONENTS

Email: suzlever@gmail.com

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REMOVAL
1. Remove the front wheel and tire.
2. Remove the stabilizer bar link assembly (A).

A.Remove the bolts(B) and stabilizer bar link(A).

If the stabilizer bar link ball joint(C) and nuts(B) turn altogether, use the pentagonal wrench to hold the
stud.

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B.Remove the stabilizer bar link on the opposite side in the same way.
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Be careful not to damage the ball joint boot.

3. Remove the stabilizer bracket(A) and bushing(B)
A.After loosen the bolts(C-in case of LH, separate pad by loosening the fixing bolts of the stabilizer bar
bracket), then remove the bracket(A) and bushing(B)

B.Remove the stabilizer bar link on the opposite side in the same way.
C.Remove the stabilizer out of the vehicle's right side.

INSTALLATION
1. Install the bushing on the stabilizer bar.

The distance between the bushing, and the part to which white paint is applied, must continue 10mm
outside the vehicle.

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2. Install the bracket on the bushing

3. Align and install the bushing with the white paint on the stabilizer bar. After tightening the bolts of the bushing
bracket temporarily, install the bushing bracket on the opposite side.

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.
4. Check the stabilizer link ball joint(A) for rotating torque.

A.If there is a crack in the dust cover, replace it and add grease.
B.Shake the stabilizer link ball joint stud several times.

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C.Mount the self-locking nut on the ball joint, Ebay

and User
thenID:measure
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the ball joint rotating torque.

Standard value
1.7~3.2 Nm (17~32 kgf·cm, 15~27 lbf·in)

D.If the rotating torque is higher than the upper limit of the standard value, replace the stabilizer link.
E.If the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it has
drag and excessive play.

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COMPONENTS

Email: suzlever@gmail.com

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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.

DISASSEMBLY
1. Remove the dust cover(A) with a flat-tipped (-) screwdriver(B).

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2. Open the dust cover and wipe off grease in the insulator(A).
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3. Using the Special Tool (J38402, A-50), compress the coil spring(A) until there is only a little tension of the
spring on the strut.

• When compress the coil spring, do not use an impact gun.

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4. Under the condition of fixed strut(A) on the vise(B), remove the front strut self-locking nut(C).
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5. Remove the insulator, spring seat, coil spring and dust cover from the strut assembly

REASSEMBLY
1. Install lower spring pad so that the protrusions fit in the holes of the spring lower seat.
2. Install the strut dust cover(A) and rubber bump(B) to piston rod.

Compress the piston rod until engaging two grooves(A,B).

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3. Compress coil spring using Special tool (J38402, A-50).

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Install compressed coil spring into shock aborber.

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 distinaish between the two marks and then install them.

2.Install the coil spring with the identification mark directed toward the knuckle.
4. After fully extending the piston rod, install the spring upper seat and insulator assembly.
5. 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.

6. Remove the Special Tool(J38402, A-50).

7. Tighten the self-locking nut to the specified torque.

Tightening torque
50~70 Nm (500~700 kgf.cm, 37~51 lbf.ft)

8. Apply grease to the strut upper bearing and install the insulator cap.

When appling the grease, be careful so that it isn't smeared on the insulator rubber.

REMOVAL
1. Remove the front wheel and tire.
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2. Detach the brake hose bracket(B) from the front strut assembly(A).
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Do not apply excessive force to the components.

3. In case of the vehicles equipped with Anti-lock Brake system, remove the wheel speed sensor(A) from the
knuckle(B).

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

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

INSTALLATION
1. Installation is the reverse of the removal procedure.

After installation, check the front wheel alignment.

DISPOSAL
1. Fully extend the piston rod.

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2. Drill a hole on the A section to remove gas from the cylinder.

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The gas coming out is harmless, but be careful of chips that may fly when drilling.

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COMPONENTS

Email: suzlever@gmail.com

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REMOVAL
1. Remove the stabilizer bar link(A) from the rear strut assembly(B).

If the ball joint(C) and nuts(D) turn altogether, use the pentagonal wrench to hold the stud(E).

2. Remove the rear stabilizer bar mounting brackets.

3. Remove the stabilizer bar link on the opposite side in the same way.
4. Remove the mounting nuts(B,C) of the exhaust pipe asse mbly(A).

5. Remove the stabilizer bar assembly.

INSTALLATION

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1. Install the bushing on the stabilizer bar.

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After matching the bushing(D) in the inside of the white painted part(A) on the stabilizer bar(C), install the
assembly.
2. Install the bracket(B) on the bushing(D).

3. Tighten the components below to the specified torque as follows.

Rear stabilizer bar mounting bracket bolts (A) :

17~26 Nm (170~260 kgf·cm, 13~19 lbf·ft)
Rear stabilizer bar link mounting nut (B) :
35~45 Nm (350~450 kgf·cm, 26~33 lbf·ft)

INSPECTION
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Check the stabilizer link ball joint(A) rotating torque.

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1. If there is a crack in the dust cover, replace it and add grease.

2. Shake the stabilizer link ball joint stud several times.
3. Mount the self-locking nut on the ball joint, and then measure the ball joint rotating torque.

Standard value
1.7~3.2 Nm (17~32 kgf·cm, 1.25~2.36 lbf·ft)

4. If the rotating torque is above the upper limit of the standard value, replace the stabilizer link.
5. If the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it has
drag and excessive play.

Email: suzlever@gmail.com

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COMPONENTS

Email: suzlever@gmail.com

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INSPECTION
1. Check the strut insulator for wear or damage.
2. Check rubber parts for damage or deterioration.
3. Check the coil spring and strut assembly for sagging and deformation.
4. Compress and extend the piston rod(A) and check that there is no abnormal resistance or unusual sound during operating.

DISASSEMBLY
1. Using the Special Tools (J38402, A-20 and A-50), compress the coil spring(A) until there is only a little tension on the strut
(B).

Do not use an impact gun.

2. Open the insulator dust cover and then remove the self-locking nut at the top end of the upper strut.
3. Remove the spring upper seat, coil spring, spring lower pad, rubber bumper and dust cover.

REASSEMBLY

Email: suzlever@gmail.com

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1. Install the spring lower pad(D) so that the protrusions(A) fit in the holes(C) in the spring lower seat(B).
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2. Install the dust cover and rubber bump at the strut.

3. Using the Special Tools (J38402, A - 20 and A - 50), compress the coil spring(A).

Do not use an inpact gun.

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4. After extending the piston rod fully, install the compressed coil spring.
5. After seating the upper and lower ends of the coil spring in the upper and lower spring seat grooves correctly, tighten the
new self-locking nut temporarily.

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

6. After aligning the hole(A) of the lower spring seat with projection part(B) of the rear insulator, assemble them.

The spring identification color mark should face down.

7. Remove the Special tool (J38402, A-20 and A-50).
8. Tighten the self-locking nut to the specified torque.

Tightening torque
40~55 Nm (400~550 kgf.cm, 29.6~40.7 lbf.ft)

REMOVAL
1. Remove the rear seat (See BD group - rear seat).
(1) Raise the rear cushion.
(2) Remove the mounting bolts between rear cushion and rear seatback.
(3) Remove the mounting bolts to both end part of rear seatback.

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 Purchased
from Ebay seller
Reveleus1

Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@gmail.com
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2. Remove the rear strut upper mounting nuts(A).

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3. Remove the rear wheel and tire.

4. Disconnect the brake hose(B) and wheel speed sensor wiring(C) from the rear strut(A).
(1) Disconnect the brake hose(B) by removing the clip(D)

(2) Disconnect the wheel speed sensor wiring(A).

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5. After unfastening stabilizer bar link nut(C), remove the stabilizer bar link(B) from the strut(A).

6. Remove the lower strut mounting bolts(A).

Be careful not to drop the rear strut.

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7. Remove the rear strut assembly.

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COMPONENTS

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REMOVAL
1. Remove the bolt (C) fixing the trailing arm (A) to the rear carrier (B).

2. Remove the bolt (C) fixing the rear suspension arm (A) to the rear carrier (B).

3. Employ the same manner described above step 1 and step 2 to the other side.

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4. After supporting the rear cross member assembly (B) with a jack (A), remove the two cross member fixing
Ebay User ID: reveleus1
bolts (C). Employ the same manner described above to the other side.

The rear cross member assembly (B) is unstable on the jack(A); be careful not to allow it to fall.

5. Lowing the jack, remove the rear cross member and rear suspension arms as an assembly.
6. Remove the two rear suspension arm-to-cross member bolts (A, B).

7. Remove the rear suspension arms.

INSTALLATION
1. Installation is in the reverse order of removal (See page SS-52).

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2. Reassemble the rear suspension arms (C) and the rear cross member (A) as shown below. Make sure that the
Ebay User ID: reveleus1
arrow mark (B) on the rear cross member (A) should place the front face of the vehicle.
Rear suspension arm (C) -to-rear carrier bolts should be temporarily tightened, and then fully tightened with
the vehicle on the ground in unloaded condition.

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SPECIAL TOOLS
Tool (Number and
Use Illustration
Name)

09216-21000 Removal & installation of

Mount bushing remover lower arm bushing (G)
and installer (Use with 09216-21200,
09545-02000)

09216-21200 Removal & installation of the

Mount bushing remover lower arm bushing (G)
and installer base (Use with 09216-21100,
09545-02000)

09532-11600 Measurement of the lower

Preload socket arm ball joint & stabilizer link
starting torque

09545-02000 Removal & installation of the

Lower arm bushing lower arm bushing (G)
remover and installer (Use with 09216-21100,
09216-21200)

09545-11000 Installation of the lower arm

Ball joint remover and ball joint
installer

09545-21100 Installation of the lower arm

Ball joint dust cover ball joint dust cover
installer

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09551-25000 Ebay User ID: reveleus1 Removal & installation of the

Trailing arm bushing trailing arm bushing
remover and installer

09551-25000
Rear suspension arm Removal & installation of the
remover and installer rear suspension arm bushing
(Use with 09545-28100)

09568-34000 Separation of the lower arm

Ball joint puller ball joint

A-20 Compression of the rear coil

Strut compressor spring
adapter (Use with J38402)

A-50 Compression of the front coil

Strut compressor spring
adapter (Use with J38402)

J38402 Compression of the front &

Strut spring compressor rear coil spring
(Use with A-50 or A-20)

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SPECIFICATIONS

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SERVICE STANDARD

Difference between left and right camber angle is within 0°30´.

Difference between left and right caster angle is also within 0°30´.

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Difference between left and right camber angle is within 0° 30´.

TIGHTENING TORQUE
Items Nm kgf·cm lbf·ft

Wheel nut 90 ~ 110 900 ~ 1100 67 ~ 82

Castle nut 200 ~ 260 2000 ~ 2600 159 ~ 192
Front strut upper mounting nut 45 ~ 60 450 ~ 600 33 ~ 44
Front strut assembly to knuckle 130 ~ 150 1300 ~ 1500 96 ~ 111
Front strut mounting self-locking nut 50 ~ 70 500 ~ 700 37 ~ 51
Lower arm ball joint to knuckle 60 ~ 72 600 ~ 720 43 ~ 52
Lower arm bush (A) mounting bolt 130 ~ 150 1300 ~ 1500 96 ~ 111
Lower arm bush (G) mounting bolt 130 ~ 150 1300 ~ 1500 96 ~ 111
Stabilizer bar bracket mounting bolt 30 ~ 45 300 ~ 450 22 ~ 33
Stabilizer link nut 35 ~ 45 350 ~ 450 26 ~ 33
Tie rod end ball joint to knuckle 24 ~ 34 240 ~ 340 18 ~ 25
Tie rod end lock nut 50 ~ 55 500 ~ 550 37 ~ 41
Rear strut upper mounting nut 30 ~ 40 300 ~ 400 22 ~ 30
Rear strut lower mounting nut 110 ~ 130 1100 ~ 1300 81 ~ 96
Rear strut mounting self locking nut 40 ~ 55 400 ~ 550 29.6 ~ 40.7
Rear stabilizer link to stabilizer bar 35 ~ 45 350 ~ 450 26 ~ 33
Rear stabilizer bar bracket bolt 17 ~ 26 170 ~ 260 13 ~ 19
Rear suspension arm tie rod nut 50 ~ 60 500 ~ 600 37 ~ 43
Rear suspension arm mounting bolt 160 ~ 180 1600 ~ 1800 118 ~ 133
Rear cross member mounting bolt 100 ~ 120 1000 ~ 1200 74 ~ 88
Trailing arm to bracket nut 100 ~ 120 1000 ~ 1200 74 ~ 88
Trailing arm bracket to body frame 40 ~ 50 400 ~ 500 30 ~ 37
Trailing arm to rear carrier mounting nut 100 ~ 120 1000 ~ 1200 74 ~ 89

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

LUBRICANTS
Item Recommended lubricant Quantity

In ball joint of lower arm Variant R-2 grease or poly lub gly 801K As required

In insulator bearing of strut SAE J310a, Chassis grease (NLGI No.0 or equivalent) As required

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COMPONENTS

Email: suzlever@gmail.com

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Ebay User ID: reveleus1

REMOVAL
1. After removing the bolt (C), detach the parking brake cable(B) which is fixed on the rear trailing arm bracket(A).

2. Remove the trailing arm mounting bolts(A,B) and the trailing arm bracket mounting bolts(C,D,E).

3. Remove the trailing arm.

REPLACEMENT
TRAILING ARM BUSHING

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1. Install the special tool (09551 - 25000) on the trailing arm(A).

Ebay User ID: reveleus1

2. Remove the trailing arm bushing.

3. Using the special tool (09551 - 25000), press-fit the rear trailing arm bushing.

Press-fit the bushing in the same way as shown in the illustration.

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INSTALLATION
1. Installation is the reverse of the removal procedures.
2. Fully tighten the trailing arm mounting bolts to the specified torque under the unloaded vehicle on the ground.

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TROUBLESHOOTING
Vehicle inspection

To assist the service advisor and the technician, check the suspension and wheel/tire condition with the questions listed
below by filling them. It serves as a place to record information as well as data from the testing to be carried out. To
begin a successful diagnosis, fill out the questions.

SYMPTOM CHART
Symptom Suspect Area Remedy (See page)

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

Loose front struts or shocks Inspect for loose nuts or bolts.

Clunk-noise from the front
Tighten to specifications.
suspension, occurs in and out of turns
See page SS-27.

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Clunk-noise from the rear suspension, Loose rearEbay

suspension components
User ID: reveleus1
Inspect for loose or damaged rear
occurs when shifting from reverse to suspension components.
drive Repair or install new components as
necessary.
See page SS-44.

Click or pop-noise from the front Worn or damaged ball joints Install new lower arm as necessary.
suspension-more noticeable over See page SS-34.
rough roads or over bumps

Click or pop-noise occurs when Worn or damaged ball joints Install new lower arm as necessary.
vehicle is turning See page SS-35.

Damaged or worn Birfield joint Repair or install a new Birfied joint as

Click or snap-occurs when
necessary.
accelerating around a corner
See DS group - driveshaft.

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

creak or rattle noise-occurs mostly Loose or bent front struts or shock See page SS-12.
over bumps or rough roads absorbers
Damaged spring or spring mounts
Damaged or worn arm bushings
Worn or damaged stabilizer bar
bushing or links

Uneven seating surface between the Repair or install a new parts as

Groaning or grinding-noise from the insulator and panel by the burrs necessary.
front strut, occurs when driving on around the strut insulator mounting See page SS-28.
bumpy roads or turning the vehicle bolts and the insulator boltes
mounting holes

Rear suspension noise - a squeak, Loose or bent rear shock absorbers Go to detailed test B.
creak or rattle noise - occurs mostly Damaged spring or spring mounts See page SS-13.
over bumps or rough roads Damaged or worn control arm
bushings

Shudder-occurs during acceleration Rear axle assembly mispositioned Check the axle mounts and Rear
from a slow speed or stop Damaged or worn front suspension suspension the rear suspension for
components damage or wear. Repair as 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.

Shimmy-most noticeable on coast/ Excessive positive caster Check the caster alignment angle.
deceleration-also hard steering Correct as necessary.
condition See page SS-58.

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Tire noise-hum/moan at constant Abnormal Ebay

wearUser
patterns
ID: reveleus1 Spin the tire and Check for tire wear.
speeds Install a new tire as necessary. Inspect
for damaged/worn suspension
components. Carry out wheel
alignment.
See page SS-58, SS-62.

Tire noise-noise tone lowers as the Out-of-balance tire Balance the tire and road test. Install a
vehicle speed is lowered new tire as necessary.
See page SS-62.

Tire noise - ticking noise, change with Nail puncture or stone in tire tread Inspect the tire. Repair as necessary.
speed See page SS-62.

Wheel and tire-vibration and noise Damaged or worn tire Go to detailed test C.
concern is directly related to vehicle See page SS-14.
speed and is not affected by
acceleration, coasting or decelerating

Tire wobble or shudder - occurs at Damaged wheel bearings Spin the tire and check for abnormal
lower speeds 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-60.

Damaged or worn suspension Inspect the suspension components

components for wear or damage. Repair as
necessary.
See page SS-27, SS-44.

Loose wheel nuts Check the wheel nuts.

Tighten to specification.
See page SS-60.

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-62

Tire shimmy or shake - occurs at Wheel/tire out of balance See page SS-58.
lower speeds
Uneven tire wear Check for abnormal tire wear. Install a
new tire as necessary.
See page SS-62.

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ExcessiveEbay
radial runout of wheel or
User ID: reveleus1
Carry out a radial runout test of the
tire wheel and tire.
Install a new tire as necessary.
See page SS-60.

Worn or damaged wheel studs or Inspect the wheel studs and wheels.
elongated stud holes Install new components as necessary.
See page SS-60.

Excessive lateral runout of the wheel Carry out a lateral runout test of the
or tire wheel and tire.
Check the wheel, tire and hub. Repair
or Install new components as
necessary.
See page SS-60.

Clean the mounting surfaces of the

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

High speed shake or shimmy-occurs Excessive wheel hub runout Go to detailed test D.
at high speeds Damaged or worn tires See page SS-17.
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-19.
Alignment
Base brake system

Steering wheel Alignment Go to detailed test F.

Steering linkage See page SS-20.
Front lower arm ball joint

Tracks incorrectly Rear suspension Go to detailed test G.

Caster See page SS-21.

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

Rear shock absor and spring See page SS-22.
assembly

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

components See page SS-22.
Springs
Suspension components
Shock absorbers

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Incorrect tire wear Tire or unbalanced wheels

Ebay User ID: reveleus1
Go to detailed test J.
Tire inflation See page SS-23.
Strut
Alignment

Vibration Wheel/tire Go to detailed test K.

Front wheel drivshaft(s) See page SS-24.
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

Vehicle leans Inflate tires to specification.

Tire/wheel
See page SS-62.
Vehicle load
Redistribute the load as necessary.
Suspension components
Visually inspect the suspension 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-19.

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
.
→ NO
The suspension system is OK. Conduct a diagnosis on other
suspect systems.

INSPECT THE STEERING SYSTEM

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1.Check
Ebay the steering
User ID: reveleus1 system for wear or damage.
Carry out a steering linkage test.
2.Inspect the tire wear pattern. See page SS-26.
● 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.
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DETAILED TEST B : REAR SUSPENSION NOISE Ebay User ID: reveleus1

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

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1.Inspect
Ebay the trailing
User ID: reveleus1 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

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1.Check
Ebay the tires
User ID: reveleus1 for missing weights.
2.Check the wheels for damage.
3..
● 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

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Measure
Ebay the pilot
User ID: reveleus1 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-27
for the front suspension or SS-43 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-44 for the rear suspension.

DETAILED TEST D : HIGH SPEED SHAKE OR SHIMMY

CONDITIONS DETAILS/RESULTS/ACTIONS

CHECK FOR FRONT WHEEL BEARING ROUGHNESS

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1.See
Ebay GIreveleus1
User ID: 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

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

Ebay User ID: reveleus1
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
.
→ NO
.

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

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Inspect the
Ebaytires
User for excessive wear or damage.
ID: reveleus1
● 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 alignment.
● Is the alignment within specification ?
→ YES
Go to
→ NO
Adjust the alignment as necessary. See page SS-58 (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.
.

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
.
→ NO
Adjust the clear vision to specification.

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INSPECT THE STEERING COMPONENTS Ebay User ID: reveleus1

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.
.

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

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.
.
→ NO
Inspect the rear suspension components for wear or damage. Repair or
Install new components as necessary.
See page SS-44 (rear suspension).

DETAILED TEST H : ROUGH RIDE

CONDITIONS DETAILS/RESULTS/ACTIONS

CHECK THE FRONT SHOCK ABSORBER

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 Purchased
from Ebay seller
Reveleus1

Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@gmail.com
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1.Raise
Ebay User ID: support
reveleus1 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-28 (front strut assembly).
→ NO
.

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-45 (rear strut assembly).
→ NO
.

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-28 and SS-45 (front/rear strut assembly).
→ 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-41, SS-55 (front/rear stabilizer bar).
→ NO
.

INSPECT THE FRONT SUSPENSION

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Inspect the front suspension components for excessive wear or

Ebay User ID: reveleus1
damage.
● Are the front suspension components worn or damaged ?
→ YES
Install new front suspension components.
See page SS-27 (front suspension).
→ NO
.

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
.

CHECK FOR CUPPED TIRE

Inspect the tires for cupping or dishing.

● Are the tires cupped or dished ?
→ YES
Balance and Rotate the tires.
→ NO
.

DETAILED TEST K : VIBRATION

CONDITIONS DETAILS/RESULTS/ACTIONS

ROAD TEST

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Accelerate the vehicle to the speed at which the customer

Ebay User ID: reveleus1
indicated the vibration occured.
● Is the vibration present ?
→ YES
.
→ 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
.
→ 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
.
→ NO
Install new front wheel bearings as necessary.
See DS group - gront 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

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For each wheel position measure, locate and mark the following
Ebay User ID: reveleus1
items.
See page SS-58 (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

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• Center- tread down to fabric due to • Underinflated tires

Ebay User ID: reveleus1 • Toe adjustment out of specification
excessive over inflated tires • Worn suspension components • Camber out of specification
• Lack of rotation • Excessive cornering speeds • Damaged strut
• Excessive toe on drive wheels • Lack of rotation • Damaged lower arm
• Heavy acceleration on drive

WHEEL AND TIRE DIAGNOSIS

Partial wear Feather edges wheels Wear pattern

• Cansed by irreqular burrs on brak • Toe adjustment out of specification • Excessive toe on non-drive wheels
drums. • Damaged or worn tie rods • Lack of rotation
• Damaged knuckle

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