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6. Install the lock washer
Install the lock washer with the surface with counterbore outwardly
and fix it on the lock nut by screw.
Remarks: If the screw installation hole on the lock washer can not
align with the screw hole on the lock nut, then it can remove the
lock washer and adjust he lock nut slightly (rotate in the direction
of Min. adjusting range ); then install the lock washer.
7. Recheck the pre-applied load
Use the spring tension meter to recheck the pre-applied load
Pre-applied load (for starting): 28-56N
If the pre-applied load does not meet the specified value, it must
remove the lock washer and adjust it by the adjusting nut.
8. Install the ring flange
a. Install the ring flange on the hub.
b. Install the adjusting washer.
c. Install the circlip.
9. Install the hub cap
a. Coat the screw of the inner hexagon bolt with the screw lock
sealant.
b. Use the inner hexagon bolt to fix the hub cap and ring flange on
the hub; tighten the bolt to the specified torque.
Tightening force: 78
5Nm
10. Install the disc brake
Install the disc brake on the steering knuckle; tighten the bolt to the
specified torque.
Tightening force: 140
10Nm
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c. Press down the upper arm and connect the upper ball pin to the
steering knuckle. Install and tighten the nut to the specified
torque.
Tightening force: 145
15Nm
d. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole when
install the split pin; the nut can be tightened but not
loosedduringthealignment.
e. Install and tighten the lower ball pin nut to specified torque.
Tightening force: 230
20Nm
f. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole when
install the split pin; the nut can be tightened but not
loosedduringthealignment.
2. Connect the stabilizer bar to the lower arm
Support the lower arm by jack; use the inner hexagon spanner to fix
the ball pin and tighten the self-locking nut to specified torque.
Tightening force: 63
5Nm
3. Connect the steering cross rod to the steering
knuckle arm
a. Tighten the slotted nut according to the specified torque.
Tightening force: 170
15Nm
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole when
install the split pin; the nut can be tightened but not
loosedduringthealignment.
4. Install the brake cover
Tightening force: 233Nm
5. Install the front hub and disc brake
(Refer to section “Front Hub”)
Page 210 of 425
clip
Front suspension (4WD)
N m: specified torque
Used component which can not be used any more.
Pregummed component
rubber sleeve
front shaft of
lower arm
disk shim
fill blockshimfill blockdisk shim
shock Absorber
front hub and steering
knuckle assembly
split pin
lower ball pinadjusting bolt
lower adjusting block
fixed arm
upper
adjusting
block
l ower arm
rear shaft of lower arm
Torsion base
torsion
bar
lower arm long bushsplit pin
upper ball pin
upper arm
shim
upper arm bush
upper arm shaft
upper arm bush
shim
front stabilizer bar
flat shim
connecting rod of stabilizer bar
flat shim
lower arm short bush
eccentric shim
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Ball pin
Check of ball pin
1. Check the lower ball pin for loose
a. Raise the front of the car by jack and support it by the frame.
b. Ensure the front wheel is in straight advancing position and step
down the brake pedal.
c. Move the arm upwardly and downwardly; check
the clearance of lower ball pin.
Max. vertical clearance: 0mm
2. Check the upper ball pin for loose move the wheel
upwardly and downwardly and check the gap of
upper ball pin.
Max. vertical clearance: 0mm
3. Check the rotation of ball pin
a. Remove the ball pin.
b. Shown as figure, shake the ball pin stud forwardly and backwardly
for several times before install the nut
c. Rotate the nut continuously by torsion meter and 2-4s for a
cycle; record the readout of torsion meter in the fifth cycle.
Tightening torque (for rotary):
Lower ball pin 0.1
4Nm
Upper ball pin 0.1
4Nm
Disassembly of ball pin
1. Remove the steering knuckle and front hub assembly
(Refer to section “Front Hub and Steering Knuckle”)
2. Remove the lower ball pin form the lower arm
3. Remove the upper ball pin from the upper arm
Page 214 of 425
d. Tighten the adjusting bolt and make the extension length of the
bolt equal to the value before disassembly.
2. For new torsion bar spring
a. Remove the wheel.
b. Coat the spline of torsion bar spring with thin grease.
c. Install the torsion bar spring on the torsion bar base.
d. Lower the lower arm to the lower limitation position; install
the adjusting arm in the torsion bar spring with the angle that
the adjusting bolt just can be screwed on the upper adjusting
block.
Remarks: It can repeat for several times until proper when
adjust the angle.
e. Tighten the adjusting bolt to the specified torque.
Nut tightening limitation: A is about 20-35mm; if A>35mm,
then it is adjusted through height of adjusting arm.
f. Install the wheel; remove the bracket; bounce the vehicle for
several times to make the suspension enters into the stable
status.
g. Rotate the adjusting bolt and adjust the ground clearance of
chassis (Refer to 4-Wheel Alignment).
Page 217 of 425
Installation of lower suspension arm
1. Installation of lower suspension arm
a. Install the rear shaft of lower arm and tighten the screw to
the specified torque.
Tightening force: 290
25Nm
b. Install the front shaft of lower arm and pretighten the nut.
2. Installation of front hub and steering knuckle
assembly
(Refer to section “Front Hub andSteeringKnuckle”)
3. Install the vibration damper on the lower suspen
sion arm Install the vibration damper on the
lower suspension arm bracket.
Tightening force: 9010Nm
4. Connect the stabi lizer barto the lower susp
ension arm.
Tightening force: 635Nm
5. Connect the steering cross rod to the steering
knuckle arm
a. Connect the steering cross rod to the steering knuckle arm.
Tightening force: 120
10Nm
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole
when install the split pin; the nut can be tightened but not
loosed during the alignment.
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6. Install the torsion bar spring
(Refer to the section “Torsion Bar Spring”)
7. Tighten the nut of front shaft of lower arm to the
specified torque
a. Install the wheel, remove the bracket and bounce the vehicle
for several times to make the vibration damper enters into the
stable status.
b. Align the assembly mark and tighten the nut to the specified
torque.
Tightening force: 240
20Nm
8. Check the wheel alignment parameter
(Refer to 4-Wheel Alignment)
Page 220 of 425
Replacement of upper arm bush
1. Remove the bush
a. Remove the bolt and washer.
b. Use the special tools to push out the bush.
c. Remove the upper arm shaft; remove another bush in same
procedure.
2. Install the bush
a. Use the special tools to press in the bush.
b. Install the upper arm shaft; use the special tools to press in
another bush.
3. Tighten the upper arm shaft to specified torque.
a. Coat the screw of both ends of upper arm shaft with the
screw lock sealant; install the washer and nut.
Remarks: Adjust the position of upper lower; make the
installation plane of ball pin is vertical to the installation
plane of upper arm shaft.
special
special
special