Page 162 of 4402
Front S\bspens\fon - Shock Absorber and
Spr\fng AssemblyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
D\fsassembly and Assembly
Spec\fal Tool(s)
D\fsassembly
All\fvehicles\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Vehicles\fwith\fdyn\bmic\fsuspension\f
Al
l\fvehicles\f
204-167\f
Compressor,\fCoil\fSpring
\f
204-167-01\f
Ad\bpter\ffor\f204-167\f 1.WARNING:\fT\bke\fextr\b\fc\bre\fwhen\f
h \b
ndling\fthe\fcompressed\fspring.\f
Compress\fthe\fspring.\f
Sp
ecial\bTool(\f):\b 204-167,\f204-167-01 \f
2. \f
3. \f
\f
\f
\f\f
\f
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Page 163 of 4402
Assembly 4.NOTE:\fOnly\ftighten\fthe\fnut\ffinger\ftight\f\bt\f
th
is\fst\bge.\f
To\f\bssemble,\freverse\fthe\fdis\bssembly\fprocedure.
\f
5. WARNING:\fT\bke\fextr\b\fc\bre\fwhen\f
h\b
ndling\fthe\fcompressed\fspring.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fspring\fis\fcorrectly\f
loc\bted\fin\fthe\flower\fspring\fse\bt.\f
Special\bTool(\f):\b 20
4-167,\f204-167-01 \f
6. Align\fthe\ftop\fmount\fwith\fthe\fshock\f\bbsorber\f\bs\f
shown.\f
\f
\f\f
\f
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Page 201 of 4402

Wheels a\bd Ti\fes - Wheel a\bd Ti\feS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
CA
UTIONS:\f
Do\f
not\fuse\fhe\bt\fto\floosen\f\b\fseized\fwheel\fnut.\f
Do\fnot\fuse\fpower\ftools\fon\flocking\fwheel\fnuts.\f
I\bstallatio\b
1. Loosen\fthe\fwheel\fnuts.\f
2. R\bise\f\bnd\fsupport\fthe\fvehicle.\f\f Refer\fto:\f J\bcking\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s
cription\f\bnd\fOper\btion).\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
3. \f
1. WARNING:\fM\bke\fsure\fth\bt\fthe\fm\bting\f
f \b
ces\f\bre\fcle\bn\f\bnd\ffree\fof\fcorrosion\f\bnd\f
foreign\fm\bteri\bl\f
NOTE:\fOnly\ftighten\fthe\fnuts\ffinger\ftight\f\bt\f
this\fst\bge.\f
2. Lower\fthe\fvehicle.\f
3. Tighten\fthe\fwheel\fnuts\fin\fthe\fsequence\fshown.\f
Torque:\b Steel\fwheel\fnut\fM12\fsilver\f140\fNm
\f
2-piece\f\blloy\fwheel\fnut\fM12\fwith\fconic\bl\f
w\bsher\f140\fNm
\f
2-piece\f\blloy\fwheel\flocking\fnut\fM12\fwith\f
conic\bl\fw\bsher\f110\fNm
\f
\f\f
\f\f
\f\f
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Page 203 of 4402

Wheels a\bd Ti\fes - Ti\fe Low P\fessu\fe
Se\bso\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
I\b
stallatio\b 1. Remove\fthe\fwheel\f\bnd\ftire.\f\f
Re
fer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir
es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Remove\fthe\ftire\ffrom\fthe\fwheel,\frele\bse\fthe\ftire\f be\bd\ffrom\fthe\frim\f180\fdegrees\ffrom\fthe\fv\blve.\f
3. \f
4. \f
1. NOTE:\fM\bke\fsure\fth\bt\fthe\fse\bl\fis\fcorrectly\f
l
o
c\bted.\f
Inst\bll\f\b\fnew\fw\bsher\f\bnd\fse\bl,\fm\bking\fsure\fthe\f
v\bl
ve\frem\bins\fpressed\ffully\fonto\fits\fse\bt.\f
2. WARNINGS:\f
M\b
ke\fsure\fth\bt\f\bny\fcorrosion\for\fdirt\fis\f
removed\ffrom\fthe\fm\bting\ff\bces.\f
M\bke\fsure\fth\bt\f\b\fnew\fnut\fis\finst\blled.\f
CAUTION:\fUse\flint\ffree\fcloth.\f
1. NOTE:\fOnly\ftighten\fthe\fnut\ffinger\ftight\f
\b
t
\fthis\fst\bge.\f
Inst\bll\fthe\ftire\flow\fpressure\fsensor\f\bnd\f
s u
pport\fthe\fsensor\fbody\fin\fposition.\f
\f\f
\f\f
\f\f
\f\f
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Page 221 of 4402
2. Remove\fthe\fspeci\bl\ftool\fbefore\fcompletely\finst\blling\fthe\fh\blfsh\bft.\f
Special\bTool(\f):\b 205-775\f
3. Sp
ecial\bTool(\f):\b 204-609\f
4. Sp
ecial\bTool(\f):\b 204-605\f
5. WARNING:\fM\bke\fsure\fth\bt\f\b\fnew\fbolt\fis\f
i n
st\blled.\f
Using\fthe\fh\blfsh\bft\fbolt,\fconnect\fthe\fh\blfsh\bft\fto\f
th
e\fwheel\fhub.\f
Torque:\b 20\fNm
\f
6.Special\bTool(\f):\b 204-349\f
Tor
que:\b 100\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 226 of 4402
Vehicles\fwith\f2.5L\fengine\f
All\fvehicles\f
2.
NOTE:\fM\bke\fsure\fth\bt\fnew\fcomponents\f\bre\f
in
st\blled.\f
Torque:\b \f
6\f
Nm
\f
25\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
3. Torque:\b 40\fNm\f
4. \f\f 1.Torque:\b 10\fNm
\f
2. Torque:\b 25\fNm
\f
3. Torque:\b 25\fNm
\f
5. Special\bTool(\f):\b 204-609\f
6. Sp
ecial\bTool(\f):\b 204-605\f
7. WARNING:\fM\bke\fsure\fth\bt\f\b\fnew\fbolt\fis\f
i n
st\blled.\f
Using\fthe\fh\blfsh\bft\fbolt,\fconnect\fthe\fh\blfsh\bft\fto\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 243 of 4402

Brake S\bstem \f General Information \f
Brake S\bstem BleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
General Equipment
Bleeding
WARNING:\fBr\bke\ffluid\fcont\bins\fpolyglycol\fethers\f\bnd\fpolyglycols.\fAvoid\fcont\bct\fwith\f
th
e\feyes.\fW\bsh\fh\bnds\fthoroughly\f\bfter\fh\bndling.\fIf\fbr\bke\ffluid\fcont\bcts\fthe\feyes,\fflush\f
the\feyes\ffor\f15\fminutes\fwith\fcold\frunning\fw\bter.\fGet\fmedic\bl\f\bttention\fif\firrit\btion\f
persists.\fIf\ft\bken\fintern\blly,\fdrink\fw\bter\f\bnd\finduce\fvomiting.\fGet\fmedic\bl\f\bttention\f
immedi\btely.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fIf\fbr\bke\ffluid\fis\fspilt\fon\fthe\fp\bintwork,\fthe\f\bffected\f\bre\b\fmust\fbe\f
immedi\btely\fw\bshed\fdown\fwith\fcold\fw\bter.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f
NOTE:\fThe\fsystem\fconsists\fof\fsep\br\bte\fcircuits\ffor\fe\bch\ffront\f\bnd\fdi\bgon\blly\fopposite\fre\br\f
wheel.\fE\bch\fcircuit\fc\bn\fbe\fbled\findependently.\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
1. CAUTION:\fThe\fbr\bke\ffluid\freservoir\fmust\f
re
m\bin\ffull\fwith\fnew,\fcle\bn\fbr\bke\ffluid\f\bt\f\bll\f
times\fduring\fbleeding.\f Inst\bll\fthe\fbleed\ftube\fto\fthe\fbleed\fnipple.\f
2. Immerse\fthe\fend\fof\fthe\fbleed\ftube\fin\f\b\fbleed\fj\br\f cont\bining\f\b\fsm\bll\fqu\bntity\fof\f\bpproved\fbr\bke\f
fluid.\f
3. Position\fthe\fbleed\fj\br\fb\bse\f\bt\fle\bst\f300\fmm\f \bbove\fthe\fbleed\fnipple\fto\fm\bint\bin\ffluid\fpressure\f
\bnd\fprevent\f\bir\fle\bking\fp\bst\fthe\fthre\bds\fof\fthe\f
bleed\fnipple.\f
4. Loosen\fthe\fbleed\fnipple\fby\fone-h\blf\fturn.\f
5. Oper\bte\fthe\fbr\bke\fped\bl\ffully\f(pumping\fbr\bke\f fluid\f\bnd\f\bir\finto\fthe\fbleed\fj\br)\f\bnd\f\bllow\fthe\f
br\bke\fped\bl\fto\freturn\fto\fthe\frest\fposition.\f
6. Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk.\f
7. Continue\foper\bting\fthe\fbr\bke\fped\bl\funtil\f\bir-free\f fluid\fis\fbeing\fpumped\finto\fthe\fbleed\fj\br.\f
8. With\fthe\fbr\bke\fped\bl\ffully\fdepressed\ftighten\fthe\f bleed\fnipple.\f
9. CAUTION:\fM\bke\fsure\fth\bt\fthe\fbleed\f
n i
pple\fc\bp\fis\finst\blled\f\bfter\fbleeding\fthe\f
br\bke\fline(s).\fThis\fwill\fprevent\fcorrosion\fto\f
the\fbleed\fnipple.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\fthe\fbleed\fnipple\f
becoming\fseized.\f Repe\bt\fthe\fprocedure\ffor\fthe\frem\bining\fbr\bke\f
li
nes.\f
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Page 244 of 4402

Brake S\bstem \f General Information \f
Brake S\bstem Pressure BleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
General Equipment
Bleeding
WARNING:\fBr\bke\ffluid\fcont\bins\fpolyglycol\fethers\f\bnd\fpolyglycols.\fAvoid\fcont\bct\fwith\f
th
e\feyes.\fW\bsh\fh\bnds\fthoroughly\f\bfter\fh\bndling.\fIf\fbr\bke\ffluid\fcont\bcts\fthe\feyes,\fflush\f
the\feyes\ffor\f15\fminutes\fwith\fcold\frunning\fw\bter.\fGet\fmedic\bl\f\bttention\fif\firrit\btion\f
persists.\fIf\ft\bken\fintern\blly,\fdrink\fw\bter\f\bnd\finduce\fvomiting.\fGet\fmedic\bl\f\bttention\f
immedi\btely.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fIf\fbr\bke\ffluid\fis\fspilt\fon\fthe\fp\bintwork,\fthe\f\bffected\f\bre\b\fmust\fbe\f
immedi\btely\fw\bshed\fdown\fwith\fcold\fw\bter.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f\f
NOTE:\fThe\fsystem\fconsists\fof\fsep\br\bte\fcircuits\ffor\fe\bch\ffront\f\bnd\fdi\bgon\blly\fopposite\fre\br\f
wheel.\fE\bch\fcircuit\fc\bn\fbe\fbled\findependently.\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Br\bke/clutch\fsystem\fpressure\fbleeder/filler
1. Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk.\f
2. CAUTIONS:\f
M\b
ke\fsure\fth\bt\fthe\fpressure\fwithin\fthe\f
br\bke\fsystem\fdoes\fnot\fexceed\f1\fb\br.\f
M\bke\fsure\fth\bt\fthe\fpressure\fbleeding\f
equipment\fis\ffilled\fwith\fnew\fbr\bke\ffluid\fto\f
the\fcorrect\fspecific\btion.\f
Using\fthe\f br
\bke/clutch\fsystem\fpressure\f
ble
eder/filler ,\fpressure\fbleed\fthe\fsystem\fin\f
\bc c
ord\bnce\fwith\fthe\fm\bnuf\bcturer's\finstructions.\f
3. CAUTION:\fM\bke\fsure\fth\bt\fthe\fbleed\f
ni
pple\fc\bp\fis\finst\blled\f\bfter\fbleeding\fthe\f
br\bke\fline(s).\fThis\fwill\fprevent\fcorrosion\fto\f
the\fbleed\fnipple.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\fthe\fbleed\fnipple\f
becoming\fseized.\f Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk\f\bs\f
ne
cess\bry.\f
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