
CHASSIS
Reinstallation
Reinstall 
the
wheel
bearing 
in
reverse
sequence 
of
removal
2
Install 
the
bearing 
outer 
race
by 
the
use 
of
a 
froot
wheel
bearing 
drift
special 
tool
ST353 
10000
Fig 
FA 
22
Installing
bearing 
outer
race
3 
Fill
the 
wheel 
hub 
and
hub
cap 
with 
multi
purpose
grease 
MIL
G2108 
or 
10924
up 
to
the
portion 
indicated
by 
asterisk 
in
Figure 
F 
A 
23
l
I
L
I
I 
P
p
r
Fig 
FA 
23
Greasing
points 
of 
hub
assembly
4 
Fill 
the
spaces 
between 
wheel
bearing 
rollers 
and
grease 
seal
lip 
pocket 
with
multi
purpose
grease 
suf
ficiently
FA
10 
Fig 
FA 
24
Filling 
spaces 
betweetJ 
wheel
bearing 
rollers
with
grease
5
Apply 
multi
purpose 
grease 
to 
the
spindle 
shaft 
and
threaded
portions 
wheel
bearing 
washer 
and 
wheel
bearing 
lock 
nut
surfaces
slightly
6 
Install 
the
wheei
bearing 
and
grease 
seal
on 
the 
wheel
hub 
and 
install
them 
on 
the
spindle
Note 
In
order 
to
provide 
the
bearing 
with 
a
proper
prepressure 
and 
to 
extend 
the
bearing 
service 
life
install 
the
wheel
bearing 
grease 
seal 
washer 
and
lock 
nut
carefully 
so 
that 
no 
dust 
and
foreign
matters 
stick
on
grease 
applied 
to 
them
Wheel
bearing
adjustment
I
Tighten 
the 
wheel
bearing 
lock 
nut 
to 
2 
2 
to 
2
4
kg 
m
15 
9 
to
174 
ft 
lb
tightening 
torque
Fig 
FA 
25
Tightening 
wheel
bearing 
lock 
nut
2
Turn 
the 
wheel 
hub 
a 
few
turns 
both 
clockwise 
and
counterclockwise 
to 
settle 
down 
the
bearing 
and
retighten 
the
wheel
bearing 
lock 
nut 
to 
the 
same
tightening
torque
3 
Return 
the 
wheel
bearing 
lock 
nut 
in
range 
from 
400
to 
700 
and
coincide 
it 
with
cotter
pin 
hole 
on 
the
spindle 

FRONT 
AXLE
FRONT 
SUSPENSION
t
t
Fig 
FA 
26
Returning 
wheel
bearing 
lock 
nut
4 
Turn 
the 
wheel 
hub 
a 
few 
turns 
both 
clockwise 
and
counterclockwise
again 
to 
allow 
the
bearing 
breaking 
in
measure
bearing 
rotation
starting 
torque
apply 
a 
cotter
pin 
to 
secure 
the 
nut 
if 
the 
measured
starting
torque 
is
within 
the 
rated 
value 
and 
install 
the 
hub
cap
hub
cap
Wheel
bearing 
rotation
starting
torque
9 
0
kg 
cm 
7 
8
in 
1b
4 
0
kg
cm 
3
4 
7
in 
1b
At 
the
hub 
bolt
1
57
kg 
3
461b
New
bearing
0 
7
kg 
1
54lb 
Used
bearing
No 
slackness
should 
exist
toward 
the 
axis 
direction
New
bearing
Used
bearing
J
o 
i
@
j 
Be
sure 
to 
remove 
the
brake
pad 
Disc
type 
brake
Correctly 
measure
starting 
force 
toward
tangential
direction
against 
the 
hub
bolt
Fig 
FA
27
Measuring 
wheel
bearing 
ro 
ation
starting 
torque
STRUT 
ASSEMBLY
The
strut
assembly
consisting 
of 
a
strut
outer
casing
with
spindle 
forms 
a
cylinder 
between 
the
piston 
rod
guide 
and
bottom 
valve
The
inner
components 
are
precisely 
assembled 
and 
no
dirt 
and
foreign 
matter
intrusions 
are
permitted 
The
components 
such
as
piston 
rod
piston 
rod
guide 
cylinder
and
bottom 
valve 
are
handled
together 
as
an
assembly
When
replacing 
them 
be
sure 
to
replace 
the 
inner
components 
as
an
assembly
1
2
3
4
5
6
7
8
9
10 
Front
spring
Bound
bumper
Piston 
rod
self
locking 
nut
Washer
Strut
mounting 
insulator
Strut
mounting 
bearing
Oil 
seal
Upper 
spring 
seat
Dust 
cover
Strut
assembly
Fig 
FA 
28 
Strut
assembly 
components
FA 
l1 

fl
i 
i
I
1
I
I 
i
2
4
L
thi7
lrr
I
1
1
Piston 
rod
2 
Gland
packing
3 
Piston 
rod
guide
4
Cylinder 
CHASSIS
ESSION
5 
Rebound 
stopper
6 
Piston
7 
Bottom 
valve
Fig 
FA 
29 
Cross 
sectional 
view
of 
strut 
assembly
and 
shock 
absorber
operation 
Disassembly
Disassemble 
and 
reassemble 
the 
strut 
assembly 
in 
a
clean
place 
so 
that 
the 
inner
components 
are
protected
from 
dirt 
and 
other
foreign 
matters
Jack
up 
the 
vehicle 
remove 
the 
wheel 
and 
remove
the 
stabilizer 
bar 
and 
tension 
rod
from 
the 
transverse 
link
Loosen 
the 
knuckle 
arm
fIxing 
bolts 
and
separate 
the
strut
assembly 
from 
the
ball
joint 
Loosen 
the 
self
locking
nuts 
on 
the
upper 
portion 
of 
the 
strut 
and 
remove 
the
strut
assembly 
See 
the 
Removal 
of 
Front 
Axle 
and
Suspension 
Assembly 
above 
for 
details
Fig 
FA 
JO
Removitlg 
ktluckle 
arm
fixitlg 
bolt
FA 
12 

CHASSIS
r
I
El
0
3 
to
1 
0 
mm
0 
0118 
to 
0
0394 
in
Fig 
FA 
47
Cross 
sectional 
vie
of 
ball
joint
Removal
1
Jack
up 
the 
vehicle
remove 
the
wheel 
and
remove
the
stabilizer 
bar 
and 
tension 
rod
from 
the
transverse 
link
Loosen
the 
knuckle 
arm
fiXing 
bolts 
and
separate 
the 
ball
joint 
from 
the
strut
assembly 
See
Removal 
of
front
axle
and
suspension
assembly 
above 
for
details
Fig 
FA 
48
Loosening 
knuckle 
arm
fixing 
bolts 
2
Loosen 
the
transverse
link
mounting 
bolt 
and
separate 
the
transverse 
link
from 
the
suspension 
member
Fig 
FA 
49
Loosening 
transverse 
link
mounting 
bolt
3
Remove 
cotter
pin 
from 
the
castle 
nut
on 
the
knuckle 
arm
loosen 
the 
castle
nut 
and
remove 
the
knuckle 
arm
from 
the 
ball
joint
J 
iIP
A
i
Fig 
FA 
50
Removing 
knuckle 
arm
4
Loosen 
the 
ball
joint 
installation 
nut 
and
remove 
the
haJJ
joint 
from
the
transverse 
Jink
5
Withdraw 
the
transverse 
link
bushing 
from 
the
transverse 
link
with 
a 
front
transverse
link
bushing
replacer 
set
special 
tools
ST36721000
ST36722000
and 
a
press
FA 
18 

FRONT 
AXLE
FRONT 
SUSPENSION
ADJUSTMENT
CONTENTS
ADJUSTMENT 
DATA
ADJUSTMENT 
OF 
WHEEL 
ALIGNMENT
ADJUSTMENT 
OF 
VEHICLE 
LEVEL 
FA 
21
FA 
22
FA 
22
1
Carry 
out
wheel
alignment 
on 
a 
flat 
surface 
with 
tire
air
pressure 
adjusted 
to 
the 
normal
pressure
2
Thoroughly 
check 
all
component 
parts 
of 
the
steering 
and
suspension 
systems 
and
repair 
or
replace
AD
JUSTMENT 
DATA
I
Wheel
alignment 
unladen
Sedan
Coupe
Camber 
5 
to 
2005
Caster 
20 
to 
1050
Toe 
in 
mm 
in 
4 
to
6
0 
16 
to 
0 
24
King 
pin 
inclination 
7055
Steering 
angle 
In 
430
Out 
360
Tire 
Pressure 
Tobe
measured 
when 
tires 
are
cold
kgfcm2 
psi
6 
00 
12 
4PR 
Front 
Rear
For 
normal
speed
Under
100 
km 
h
or 
60 
MPH
For
high 
speed
Over 
100 
km 
h
or 
60 
MPH
15SSR 
12
Option 
Front 
Rear 
1
2 
1 
2
17
17
1
5 
1 
5 
21 
21
I
7
I 
7 
24 
24
Front 
Rear
5 
00 
12 
4 
6 
R 
ULT
Unloaded 
Option
For 
normal
speed
Under 
100 
km 
h 
or 
60
MPH
For
high 
speed
Over 
100 
km 
h 
or
60 
MPH
Loaded
For 
normal
speed
Under 
100 
km 
h
or 
60 
MPH
FA 
21 
ADJUSTMENT 
OF 
TOE 
IN
ADJUSTMENT 
OF
STEERING 
ANGLE 
FA 
22
FA 
22
defective
parts 
before
starting 
the 
wheel
alignment
3 
The 
camber
and 
caster
angles 
are
preset 
and 
cannot
be
adjusted 
Adjust 
the
toe 
in
and 
vehicle 
level
only
Van
Van
Heavy 
duty 
spring
45 
to 
1045 
45
to 
1045
1005 
to
2005 
40 
to 
1040
5 
to 
7 
5 
to 
7
0 
20 
to 
0
28 
0
20 
to 
0 
28
7045 
7045
430 
430
360 
360
1 
2
1
2 
I 
7
I 
7
1 
5 
1 
5 
21 
21
1
2 
1 
5
17 
21
1 
5 
1 
8 
21 
26
1 
2 
2 
5
17 
36 

CHASSIS
For
high 
speed
Over 
100 
km 
h 
or 
60 
MPH
ADJUSTMENT 
OF 
WHEEL
ALIGNMENT
Use 
a
turning 
radius
gauge 
and
alignment 
gauge 
for
the
measurement
2
Carry 
out 
wheel
alignment 
on
a 
flat 
surface 
with 
tire
air
pressure 
adjusted 
to 
the
normal
pressure
ADJUSTMENT 
OF 
VEHICLE
LEVEL
Vehicle 
level 
is
adjusted 
by 
changing 
springs
ADJUSTMENT 
OF 
TOE 
IN
Measure 
toe 
in 
with 
a 
toe 
in
gauge
2
Loosen 
the 
nut 
indicated
by 
arrow 
mark
in
Figure
FA 
56 
and
adjust 
the 
side 
rod
adjusting 
bar 
so 
that
distance 
L
between 
both 
side 
side 
rod 
ball
joint 
centers
is 
296 
8 
mm 
11
7 
in
I 
1
I 
Locking 
nu
t
I 
2
I 
Side 
rod
adjusting 
bar
I
Fig 
FA 
56
Adjusitng 
toe 
in 
1
5 
2
8 
21 
40
ADJUSTMENT 
OF
STEERING
ANGLE
1 
Place 
the
front 
wheels 
on
turn 
table
2 
Adjust 
both 
side
steering 
angle 
adjusting 
bolts
indicated
by 
arrow 
mark 
and 
set 
them 
al
the 
rated
steering 
angle
Note 
8
Make 
sure 
that 
clearance 
between 
tire 
tension
rod 
is 
30 
mm 
11 
181 
in 
or 
more
b 
When 
the 
clearance 
is 
less 
than 
30 
mm 
1 
181
in 
inaease 
the 
clearance
by
extending 
the
stopper
bolt
Upon
completion 
of 
the
adjustment 
max
imum
height 
of 
the
stopper 
bolt 
should 
be 
27 
5
mm 
1 
083 
in
Fig 
FA 
57
Steering 
angle 
adjusting 
bolt
FA 
22 

FRONT 
AXLE 
FRONT 
SUSPENSION
SERVICE 
DATA 
AND
SPECIFICATIONS
Wheel
alignment 
unladen
Sedan
Van 
Van
Coupe 
Heavy 
duty 
spring
Camber 
50 
to 
2005 
45
to 
1 
45 
45 
to 
1045
Caster 
20 
to 
1050 
r005
to 
2005 
40 
to 
1040
Toe 
in
mm 
in 
4 
t06 
5
to 
7 
5 
to 
7
0 
08 
to 
032 
0 
20
to 
0 
28 
0 
20
to 
0 
28
King 
pin 
inclination 
7055 
7045 
7045
Steering 
angle 
In 
430 
430 
430
Out 
360 
360
360
Tire 
Pressure 
Tobe 
measured 
when 
tires 
are 
cold
kg 
cm2
psi
6 
00 
12
4PR 
Front 
Rear
For
normal
speed
Under 
100 
km 
h 
or 
60 
MPH 
1 
2 
1
2 
17
17 
1 
2 
1
2
17 
17
For
high 
speed
Over 
100 
km
h 
or 
60 
MPH
155SR 
12
Option 
Front 
Rear
5
00 
12 
4 
6
PR 
ULT
Unloaded 
1 
5 
1
5 
21 
21
1
7
1 
7
24 
24
Option 
Front 
Rear 
1 
5 
1 
5 
21 
21
For 
normal
speed
Under 
100 
km 
h 
or 
60
MPH
For
high 
speed
Over 
100 
km
h 
or 
60 
MPH
Loaded 
1
2
1
5 
17 
21
1
5 
1 
8 
21 
26
For 
normal
speed
Under 
100 
km 
h 
or 
60
MPH
For
high
speed
Over 
100
km 
h
or 
60 
MPH 
1 
2 
2 
5
17 
36
1
5 
2
8 
21 
40
Coil 
effective 
turns 
6
25
Free
length
Installed
height 
load 
mm 
in
mm 
in
kg 
338
i 
10
133 
0394
203i5 
7 
99 
iO 
1969
200 
441
Spring 
constan 
t
kgfmm 
lb 
in 
1 
6 
89 
6
FA
23 

CHASSIS
Strut
assembly
Strut 
outer
diameter
Piston 
rod 
diameter 
mmlin
nml 
in 
45 
17
7
18 
0 
709
15 
0 
984
Piston 
diameter
mmlin
Damping 
force 
at
piston 
speed 
0
3 
m 
sec
Expansion
kg 
Ib
Compression 
kg 
lb 
48 
106
22 
48 
5
Piston 
rod
Bend
limit
Wear 
limit 
mm 
in
0 
1 
0
0039
mm 
in
0
025 
0 
0010
Piston
cylinder
Bend 
limit
Wear 
limit
inside 
mm 
in
mm 
in 
0 
2 
0
0079
0 
1 
0 
0039
17 
0
669
Stabilizer 
bar 
diameter
mm 
in
Front 
wheel
bearing 
rotation
starting
torque
kg 
cm 
in 
lb
Ball
joint 
shaking 
torque 
kg 
cm 
in 
lb
Ball
joint 
end
play
axial
direction 
mm 
in 
9 
0 
7
8
35 
to 
60 
30
4 
to 
52 
1
0
3 
to 
1 
0 
0 
0118
to 
0
0394
TIGHTENING
TORQUE
Front 
axle
Brake
disc 
rotor 
and
hub
assembly
tightening 
torque
Wheel
bearing 
lock
nut
Disc 
brake
caliper 
fixing 
bolt
Buffle
plate 
installation 
screw
Brake
disc
assembly 
installation 
bolt 
kg 
m 
ft 
lb
4
4
to 
5 
9 
31
8
to 
42 
7
2 
2 
to
2
4
15 
9 
to 
174
4 
6
to 
6 
1
33
3 
to 
44 
1
0
3 
to 
0
4
2 
1 
to 
2 
9
2 
7
to 
3 
7
19
5 
to 
26 
8
Strut
assembly
Gland
packing 
tightening 
torque
Piston 
rod
self
locking 
nut
Upper 
support 
nut 
8 
0
to 
11
0 
57
8 
to 
79 
5
3 
6
to 
4 
5
26 
0
to 
32 
5
1
6 
to 
2 
1
I 
1 
6 
to 
15 
2
Transverse 
link
and 
ball
joint
Bolts 
used 
to 
install 
the
knuckle 
arm
to 
strut
Ball
joint 
castle 
nut
Bolts 
used 
to
install 
the 
transverse 
link 
to
ball 
4 
6 
to
6 
1 
33
3 
to
44
1
5
5 
to 
7 
4 
39 
8
to 
53 
5
FA 
24