Page 721 of 1681

1.
Knuckle Removal
Loosen the wheel nuts slightly.
Raise the front of vehicle. and support it with safetystands in the proper locations {see section l ).
B€move the wheel nuts and front wheel.
SPINDLE NUT22 x 1.5 mmReplace.
Raise the locking tab on the
remove the nut.
spindle nut. then
Remove the brake hose mounting bolts.
Remove the caliper bracket mounting bolts, andhang the caliper to one side.
CAUTION: To pravant accidental damage to thgcaliper or braks hoso, use a shqrt piece of wirs tohsng the c8liper flom the undercarriage.
CALIPER BRACKET MOUNTING BOLTS12 x 1.25 mm
7, Remove the 6 mm brake disc retaining screws.
BRAKE DISCCheck for wear and rust.Inspection, section j9.
8. Screw the two I x L25 mm bolts into the disc topush it awav from the hub.
NOTE: Turn each bolt two turns at a time to pre-
vent cocking the disc excessively.
Remove the brake disc from the knuckle.
Check the front hub for damage or cracks.
Remove the wheel sensor wire bracket, thenremove the wheel sensor lrom the knuckle (for vehi-cles with ABS).
NOTE: Do not disconnect the wheel sensor connec-ror.
4.
6.
10.
11.
WHEEL SENSOFWIRE BRACKET
FRONT WHEEL
8 x 1.25 mm BOLTS
WHEEL SENSOR(cont'd)
Page 724 of 1681
Front Suspension
Knuckle/Hub (cont'd)
fl
l
Ili
Wheel Bearing Replacement
NOTE; Replace the bearing with a new one after
removal.
1. Separate the front hub from the knuckle using the
specialtools and a press as shown.
CAUTION:
. Take cale not to distort tho splssh guard,
. Hold onto ths hub to ko6p it lrom talling whon
prossed clear,
KNUCKLE
FRONT HUB
Remove the circlip and the splash guard from the
knuckle.
SPLASH GUARDCheck for bending and damage
18-14
FRONT HUB
3. Press the wheel bearing out of the knuckle using the
soecialtools and a Dress as shown.
DRIVER07749 - 0010000
ATTACHMENT.52x68mm07746 - 0010500
Remove the wheel bearing inner race trom the front
hub using the specialtool and a commercially-avail-
able bearing separator as shown.
Press HUB D|S/ASSEMBLY TOOL07GAF - SE00100
BEARINGSEPARATOR, 0 ro 4 1/2 in.(Commercially
available)
Page 725 of 1681
\
NOTE; Wash the knuckle and hub thoroughly in high
flash point solvent before reassembly.
5. Press a new wheel bearing into the knuckle using
the old bearing, a plate and a p.ess.
NOTE: Press the wheel bearing into the knuckle
with the pack seal (metal color) toward the inside. Be
careful not to damage the sleeve of the pack seal.
Installthe circlip securely in the knuckle groove.
SCREWS5x0.8mm4.9 N'm (0.5 kgf.m,3.5lbtftl
SPLASH GUARO
7. Install the splash guard and tighten the screws.
18-15
Installthe front hub on the knuckle using the special
tools and a press as shown,
CAUTION: Tako csro not to distort tho splash guard.
pre3s
DRIVER I0??a9 - 0010000 v
ATTACHMENT,62x68mm07746 - 00t0500
SPLASH GUARD
KNUCKLE
FRONT HUB
{cont'd)
Page 726 of 1681

Front Suspension
Knuckle/Hub (cont'd)
Knuckle lnstallation
1. lnstall the knuckle on the driveshaft.
2. lnstall the knuckle on the lower arm and the tie-rod,
then tighten the nuts and install new cotter pins.
CAUTION:
. Be carelul not to damage tho ball ioint boot.
a Torque the castls nut to the lowel torque spgci-
fication, then tight€n it only far enough to align
the slot with the pin hole. Do not align the nut
by loosening.
NOTE: Wipe off the grease before tightening the
nut at the ball joint.
NUT
ri
10 x 1.25 mm4il N.m (4.{ kgtm,32lbf.ftl
On reassembly,bend the cotter pin
as shown.
CASTLE NUT12 x 1 .25 mm49 - 59 N.m (5.0 - 6.0 kgf m, 36 -,|i| lbf ft)
3. Install the knuckle on the upper arm, then tighten
the castle nut and install a new cotter Din.
COTTER PINReplace.On reassembly,bend the cotter pin
CASTLE NUT12 x 1.25 mm39 - 47 N.m{4.0 - 4.8 kgf.m,29 - 3s rbr.ft)
;
, 'ar
COTTER PIN
18-16
4.Install the wheel sensor with the sensor mounting
bolts (tor vehicles with ABS).
lnstall the sensor wire with the two 5 mm bolts (for
vehicles with ABS).
NOTE: Be careful when installing the sensors to
avoid twisting wires.
6 mm BOLTS9.8 N.m 11.0 kgf.m,7 lbf.ftl
v_)
SENSOR MOUNTINGBOLTS9.8 N.m (1.0 kgf.m,7.2 lbl.ftl
6. lnstall the brake disc with the 6 mm brake disc retain-
Ing screws.
NOTE: Before installing the brake disc, clean the
mating surfaces of the front hub and the brake disc.
6 mm BRAKE DISCRETAINING SCREWS9.8 N.m 11.0 kgl.m, 7.2 lbf'ftl
Page 727 of 1681

Lower Ball Joint Replacement
7.Install the brake caliper with the caliper bracket
mounting bolts.
Install the brake hose with the brake hose mounting
bolts.
CAUTION: Bo careful not to twist the hose more
than ngcsssary.
BRAKE HOSEMOUNNNG BOLTS
CALIPER BRACKET MOUNTING BOLTS
12 x 1.25 mm108 N.m (11.0 kgf m,80 lbtftl
\9.
10.
lnstall a new spindle nut, then tighten the nut.
Installthe wheel with the wheel nuts
NOTE: Before installing the wheel, clean the mating
surfaces of the brake disc and the wheel.
FRONT WHEEL
WHE€L NUT12 x 1.5 mm108 N.m {11.0 kgf.m,80 lbtft)22 x 1.5 mm181 N.m 118.5 kgt m, 134 lbl.ftlReplace.
NOTE: After tightening, us€ a drift tostake the spindle nut shoulder againstthe driveshaft.
11. Check the tront wheel alignment and adjust if nec-
essary (see page l8-4).
1.
2.
4.
5.
Remove the knuckle (see page 18-11).
Remove the boot by prying the set ring off.
Check the boot for deterioration and damage,
replace if necessary.
Install the special tools on the ball joint and tighten
the castle nut.
Position the special tools over the ball joint asshown then set the assembly in a vise. Press the
ball joint out of the knuckle.
07JAF - SH20200
Place the balljoint in position by hand.
Install the special tools over the ball joint as shown,
then press the ball joint in.
BALL JOINT INSTALLER BASE07965 - 5800200
6.
7.
(cont'd)
18-17
Page 728 of 1681
Front Suspension
Lower, Ball Joint Replacement
(confd)
8. Install the ball joint boot and set ring using the spe-
cial tool.
9.
10.
Install the knuckle (see page 18-161.
Check the tront wheel alignment and adjust if nec-
essary (see page 18-4),
BALL JOINT BOOT CLIP GUIDE
18-18
Page 731 of 1681

lnstallation
CAUTION: Th€ vehiclo should bs on the ground b€fore any bolts or nuis connectod to rubber mounis or bushings aro
tightened.
NOTE:
. Wipe off thedirt,oil or gr€ase on the threads before tightening the fasteners.
. The right and left damper forks are not interchangeable. The left damper fork is ma.ked with "VL" while the righr
damoer fork is marked with "VR".
. The right and left upper arms are not interchangeable. The left upper arm is marked with "SRZ-L" while the right arm is
marked with "SRZ-R".
. Before tightening the upper and lower mounting nuts on the stabilizer link, adjust the location ot the link with the sus-
pension under vehicle load.
. When installing the radius arm washers, the "FR" mark faces the front ofthe car.
. After installing the suspension a rm, check the front wheel alignmentand adjust if necesssry (see page 18-4).
SELF-LOCKING NUT12 x 1.25 nn64 N.m {6,5 kg{.m, 47Replace.
STABILIZER BARAlign the stabilazer markwith end of stabilizer
BOLT
STABILIZER EUSHING
SELF.LOCKING NUTI x 1.25 mm22 N.m 12.2 kgt m, 16 lbf.ft)Replace.
FLANGE BOLT12 x 1.25 mm
FLANGE NUTI x 1.25 mm22 N.m {2.2 kgt m. 16 lbf.ft}
BADIUS ARM WASHER B{SMALL I.D.)
\64 N.m {6.5 kg{.m, 47 lbt.ft) .SELF.LOCKING NUT14 x 1.5 mm83 N.m {8.5 kgI.m, 61 lbl.ftlReplace.
RAOIUS ARM WASHER A{LARGE I.O.I
.@]
SILICONE GREASERUBBER BUSHING
FLANGE BOLTS14 x 1.5 mm89 N.m {9.1 kgf.m, 66 lbtft)
RS, LS Modebi
SELF.LOCKING NUT8 x 1.25 mm22 N.m (2.2 kg,f.m. 16lbtftl
SELF.LOCKING NUTI x I .25 mm22 N m {2.2 kgt'm, 15 lbf.ft)Replace.
14 x 1.5 mm89 N m {9.1 kgf m,66lblft)
SELF-LOC(ING NUTl0 x 1.25 mm29 N.m 13.0 kgf.m,22 lbtftlReplace.Hold the balljoint pin using ahex wrench, and tighten the self-locking nut.
FLANGE BOLT10 x 1.25 mm43 N.m {4.4 kgl.m, 32lbf.ft}
SELF-LOCKING NUT12 x 1.25 mm64 N.m {6.5 kgf.m, 47 lbtftlReplace.
SELF-LOCKING NUT 8 x 1.25 mm22 N.m {2.2 kgI m, 16lbf.ft)
STABILIZER END RUBBER BUSHINGSNote the directionof the bushinas.
Replace.Before tightening the self locking nuts, position the ball joint pinat the center of the range in which the pin can be moved with thesuspension under vehicle load.
MARK
SILICONE GREASE
1A-21
Page 732 of 1681

Front Damper
FLANGE BOLT10 x'1.25 mm
1.
4.
Removal
Remove thefrontwheels (see page 18-'11).
Remove the brake hose mounting bolts from the
damper.
Remove the flange bolt.
Remove the flange bolt and self-locking nut, then
remove the damper fork.
MOUNTING BOLT{8 x 16 mm)
Disassembly/lnspection
Disassembly
1. Compress the damper spring with the spring com-
pressor according to the manufacturer's instruc-
tions. then remove the self-locking nut.
CAUTION: Do nol compros3 tho 3pring morc than
nocessary to romovo th€ nut.
DAMPER FORK
FLANGE BOLT
SELF.LOCKING10 x 1.25 mmReplace.
COMPRESSORIlComm.rci.lly .Yrll.blclARAN|CKO T/N MST-580A, T/N 72IX',or aouivalant
Remove the damper by removing the two flange
n uts.
2, Remove the spring compressor, then disassemble
the damper as shown on the neld page.
Inspection
1. Reassemble all parts, exceptthe spring,
2, Push on the damper as shown.
3. Check for smooth operation through a full stroke,
both compression and extension.
NOTE: The damper should move smoothly. lf it
does not (no compression or no extension), the gas
is leaking, and the damper should be replaced.
Check for oil leaks, abnormal noises or binding dur-
ing these tests.
BMKE HOSE MOUNTING BOLT(8 x 20 mml
/GS, GSR, Type R Mod6ls: \l8x25mm I
18-22