Almera Tino V10 (2003 year). Manual — part 240
NOTES
FRONT & REAR SUSPENSION
CONTENTS
FRONT SUSPENSION . . . . . . . . . . . . . 2
Precautions . . . . . . . . . . . . . . . . ..2
. . . . . . . . . . . . . . .2
Preparation . . . . . . . . . . . . . . . . ..2
. . . . . . . . . . 2
. . . . . . . . 2
Noise, Vibration and Harshness (NVH)
Troubleshooting . . . . . . . . . . . . . . ...4
. . . . . . . 4
Components. . . . . . . . . . . . . . . . .5
On-vehicle Service. . . . . . . . . . . . . ...6
. . . . . . . . ...6
. . . . . . . . . . . ...6
. . . . . . . . . . . . . ...8
. . . . . . . . . .8
Coil Spring and Shock Absorber . . . . . . . ...10
. . . . . . . . . . . . . ...10
. . . . . . . ... 11
. . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . ... 11
. . . . . . . . . . . . . . . .12
Stabilizer Bar . . . . . . . . . . . . . . . .12
. . . . . . . ...12
Transverse Link and Lower Ball Joint . . . . . ...13
. . . . . . . ...13
. . . . . . . . . . . . . . ...13
Service Data and Specifications (SDS). . . . . .15
GENERAL SPECIFICATIONS (FRONT)
. . . . . .15
FRONT WHEEL ALIGNMENT (UNLADEN*1)
. . . .15
. . . . . . . . . . . ...15
. . . . . ...16
. . . . . . . . . . . . . 16
. . . . . . . . . . . . ...16
REAR SUSPENSION. . . . . . . . . . . . . .17
Precautions . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . ...17
Preparation . . . . . . . . . . . . . . . . 17
. . . . . . . ..17
Noise, Vibration and Harshness (NVH)
Troubleshooting . . . . . . . . . . . . . . .17
Components. . . . . . . . . . . . . . . ...18
On-vehicle Service. . . . . . . . . . . . . .19
. . . . . . . . ...19
. . . . . . . . . .19
Removal and Installation . . . . . . . . . . ...22
. . . . . . . . . . . . . . . ...23
. . . . . . . . . . . . . . 23
Coil Spring and Shock Absorber . . . . . . . ...23
. . . . . . . ...23
. . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . ...24
. . . . . . . . . . . . . . . .24
Torsion Beam, Lateral Link and Control Rod . . . 25
. . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . ...25
. . . . . . . . . . . . . . . .25
Service Data and Specifications (SDS). . . . . .27
. . . . . ...27
REAR WHEEL ALIGNMENT (UNLADEN*)
. . . . .27
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SBR686C
Precautions
PRECAUTIONS
NLSU0001
I
When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
Oil will shorten the life of rubber bushes. Be sure to wipe
off any spilled oil.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
I
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
I
Use flare nut wrench when removing or installing brake
tubes.
I
Always torque brake lines when installing.
I
Lock nuts are unreusable parts; always use new ones.
When replacing, do not wipe the oil off the new lock nut
before tightening.
Preparation
SPECIAL SERVICE TOOLS
NLSU0002
Tool number
Tool name
Description
HT72520000
Ball joint remover
NT146
Removing tie-rod outer end and lower ball joint
COMMERCIAL SERVICE TOOLS
NLSU0003
Tool name
Description
Attachment Wheel align-
ment
NT148
Measure wheel alignment
a: Screw M24 x 1.5 pitch
b: 35 mm (1.38 in) dia.
c: 65 mm (2.56 in) dia.
d: 56 mm (2.20 in)
e: 12 mm (0.47 in)
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing each brake piping
a: 10 mm (0.39 in)
FRONT SUSPENSION
Precautions
SU-2
Tool name
Description
Spring compressor
NT717
Removing and installing coil spring
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FRONT SUSPENSION
Preparation (Cont’d)
SU-3
Noise, Vibration and Harshness (NVH)
Troubleshooting
=NLSU0004
NVH TROUBLESHOOTING CHART
NLSU0004S01
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
—
—
—
SU-10,
22
SU-8
—
—
—
—
—
—
Refer
to
SUSPENSION
in
this
chart.
Refer
to
TIRES
in
this
chart.
Refer
to
ROAD
WHEEL
in
this
chart.
ST
-5
Possible Cause
and SUSPECTED
PARTS
Improper
installation,
looseness
Shock
absorber
deformation,
damage
or
deflection
Bushing
or
mounting
deterioration
Parts
interference
Spring
fatigue
Suspension
looseness
Incorrect
wheel
alignment
Stabilizer
bar
fatigue
Out-of-round
Imbalance
Incorrect
air
pressure
Uneven
tire
wear
Deformation
or
damage
Non-uniformity
Incorrect
tire
size
DRIVE
SHAFT
AXLE
SUSPENSION
TIRES
ROAD
WHEEL
BRAKES
STEERING
Symptom
SUSPENSION
Noise
×
×
×
×
×
×
×
×
×
×
×
×
Shake
×
×
×
×
×
×
×
×
×
×
×
Vibration
×
×
×
×
×
×
×
×
×
Shimmy
×
×
×
×
×
×
×
×
×
×
Judder
×
×
×
×
×
×
×
×
Poor quality
ride or han-
dling
×
×
×
×
×
×
×
×
×
×
TIRES
Noise
×
×
×
×
×
×
×
×
×
×
×
×
×
Shake
×
×
×
×
×
×
×
×
×
×
×
×
×
Vibration
×
×
×
×
×
×
Shimmy
×
×
×
×
×
×
×
×
×
×
×
×
×
Judder
×
×
×
×
×
×
×
×
×
×
×
×
Poor quality
ride or han-
dling
×
×
×
×
×
×
×
×
×
×
ROAD
WHEEL
Noise
×
×
×
×
×
×
×
×
×
×
Shake
×
×
×
×
×
×
×
×
×
×
Shimmy,
Judder
×
×
×
×
×
×
×
×
×
Poor quality
ride or han-
dling
×
×
×
×
×
×
×
×
: Applicable
FRONT SUSPENSION
Noise, Vibration and Harshness (NVH) Troubleshooting
SU-4
Components
NLSU0005
NAX008
1.
Front suspension member
2.
Stabilizer bar
3.
Transverse link
4.
Member pin stay
5.
Knuckle
6.
Strut assembly
7.
Coil spring
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FRONT SUSPENSION
Components
SU-5
SMA525A
On-vehicle Service
FRONT SUSPENSION PARTS
NLSU0006
Check front axle and front suspension parts for excessive play,
cracks, wear or other damage.
I
Shake each front wheel to check for excessive play.
I
Make sure that cotter pin is inserted.
I
Retighten all axle and suspension nuts and bolts to the speci-
fied torque.
Tightening torque:
Refer to “FRONT SUSPENSION”, SU-5.
SFA392B
I
Check strut (shock absorber) for oil leakage or other damage.
I
Check suspension ball joint for grease leakage and ball joint
dust cover for cracks or other damage.
If ball joint dust cover is cracked or damaged, replace trans-
verse link.
SFA818AA
I
Check spring height from top of wheelarch to the ground.
a)
Vehicle must be unladen*, parked on a level surface, and tires
checked for proper inflation and wear (tread wear indicator
must not be showing).
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
b)
Bounce vehicle up and down several times before measuring.
Standard height: Refer to SDS, SU-16.
c)
Spring height is not adjustable. If out of specification, check for
worn springs or suspension parts.
SSU031
I
Check suspension ball joint end play.
a)
Jack up front of vehicle and set the stands.
b)
Clamp dial indicator onto transverse link and place indicator tip
on lower edge of brake caliper.
c)
Make sure front wheels are straight and brake pedal is
depressed.
d)
Place a pry bar between transverse link and inner rim of road
wheel.
e)
While raising and releasing pry bar, observe maximum dial
indicator value.
Vertical end play: 0 mm (0 in)
f)
If ball joint movement is beyond specifications, remove and
replace it.
BALANCING WHEELS
NLSU0042
I
Adjust wheel balance using road wheel center.
Wheel balance (Maximum allowable unbalance):
Refer to SDS, SU-16.
FRONT SUSPENSION
On-vehicle Service
SU-6
SFA975B
Preliminary Inspection
NLSU0042S01
Aluminum wheel
NLSU0042S0101
1.
Check tires for wear and improper inflation.
2.
Check wheels for deformation, cracks and other damage.
If deformed, remove wheel and check wheel runout.
a.
Remove tire from aluminum wheel and mount on a tire balance
machine.
b.
Set dial indicator as shown in the illustration.
Wheel runout (Dial indicator value):
Refer to SDS, SU-16.
3.
Check front wheel bearings for looseness.
4.
Check front suspension for looseness.
5.
Check steering linkage for looseness.
6.
Check that front shock absorbers work properly.
7.
Check vehicle posture (Unladen).
SFA981B
Steel wheel
NLSU0042S0102
1.
Check tires for wear and improper inflation.
2.
Check wheels for deformation, cracks and other damage.
If deformed, remove wheel and check wheel runout.
a.
Remove tire from steel wheel and mount wheel on a tire bal-
ance machine.
b.
Set two dial indicators as shown in the illustration.
c.
Set each dial indicator to 0.
d.
Rotate wheel and check dial indicators at several points
around the circumference of the wheel.
e.
Calculate runout at each point as shown below.
Radial runout = (A + B)/2
Lateral runout = (C + D)/2
f.
Select maximum positive runout value and the maximum
negative value.
Add the two values to determine total runout.
In case a positive or negative value is not available, use the
maximum value (negative or positive) for total runout.
If the total runout value exceeds the limit, replace steel wheel.
Wheel runout:
Refer to SDS, SU-16.
3.
Check front wheel bearings for looseness.
4.
Check front suspension for looseness.
5.
Check steering linkage for looseness.
6.
Check that front shock absorbers work properly.
7.
Check vehicle posture (Unladen).
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FRONT SUSPENSION
On-vehicle Service (Cont’d)
SU-7
SMA829C
TIRE ROTATION
NLSU0043
I
Do not include the T-type spare tire when rotating the tires.
Wheel nuts:
: 98 - 118 N·m (10.0 - 12.0 kg-m, 72 - 87 ft-lb)
FRONT WHEEL ALIGNMENT
NLSU0045
Before checking front wheel alignment, be sure to make a prelimi-
nary inspection (Unladen*).
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.
SRA096A
Camber, Caster and Kingpin Inclination
NLSU0045S01
Camber, caster and kingpin inclination are preset at factory
and cannot be adjusted.
1.
Measure camber, caster and kingpin inclination of both right
and left wheels with a suitable alignment gauge.
Camber, caster and kingpin inclination:
Refer to SDS, SU-15.
2.
If
camber,
caster
or
kingpin
inclination
is
not
within
specification, inspect front suspension parts. Replace dam-
aged or worn out parts.
AFA050
Toe-in
NLSU0045S02
Measure toe-in using the following procedure.
WARNING:
I
Always perform the following procedure on a flat surface.
I
Make sure that no person is in front of the vehicle before
pushing it.
1.
Bounce front of vehicle up and down to stabilize the posture.
2.
Push the vehicle straight ahead about 5 m (16 ft).
3.
Put a mark on base line of tread (rear side) of both tires at the
same height as hub center. These are measuring points.
SFA234AC
4.
Measure distance “A” (rear side).
5.
Push the vehicle slowly ahead to rotate the wheels 180
degrees (1/2 turn).
If the wheels have rotated more than 180 degrees (1/2 turn), try
the above procedure again from the beginning. Never push
vehicle backward.
6.
Measure distance “B” (front side).
Total toe-in:
Refer to SDS, SU-15.
FRONT SUSPENSION
On-vehicle Service (Cont’d)
SU-8
SFA486A
7.
Adjust toe-in by varying the length of steering tie-rods.
a.
Loosen lock nuts.
b.
Adjust toe-in by screwing tie-rods in and out.
Standard length “L”:
Refer to ST-27, “SDS”.
c.
Tighten lock nuts to specified torque.
Lock nut tightening torque:
Refer to ST-16, “POWER STEERING GEAR AND LINK-
AGE”.
SFA439BA
Front Wheel Turning Angle
NLSU0045S03
1.
Set wheels in straight-ahead position. Then move vehicle for-
ward until front wheels rest on turning radius gauge properly.
2.
Rotate steering wheel all the way right and left; measure turn-
ing angle.
Do not hold the steering wheel on full lock for more than
15 seconds.
Wheel turning angle (Full turn):
Refer to SDS, SU-15.
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FRONT SUSPENSION
On-vehicle Service (Cont’d)
SU-9
Coil Spring and Shock Absorber
COMPONENTS
=NLSU0008
NAX009
1.
Strut mount upper plate
2.
Strut spacer
3.
Strut mount insulator
4.
Thrust bearing
5.
Upper spring seat
6.
Upper rubber seat
7.
Bound bumper rubber
8.
Coil spring
9.
Shock absorber
10. Wheel hub and steering knuckle
11. Cotter pin
12. Transverse link
13. Washer
14. Connecting rod
15. Member pin stay
16. Suspension member
17. Washer
18. Bush
19. Clamp
20. Stabilizer
FRONT SUSPENSION
Coil Spring and Shock Absorber
SU-10
SFA956A
REMOVAL AND INSTALLATION
=NLSU0009
I
Remove shock absorber fixing bolt and nut (to hoodledge).
I
Do not remove piston rod lock nut on vehicle.
SSU002
DISASSEMBLY
NLSU0010
1.
Set shock absorber on vise, then loosen piston rod lock nut.
I
Do not remove piston rod lock nut at this time.
2.
Compress spring with Tool so that shock absorber mounting
insulator can be turned by hand.
WARNING:
Make sure that the pawls of the two spring compressors are
firmly hooked on the spring. The spring compressors must be
tightened alternately so as not to tilt the spring.
SSU003
3.
Remove piston rod lock nut.
INSPECTION
NLSU0011
Shock Absorber Assembly
NLSU0011S01
I
Check for smooth operation through a full stroke, both com-
pression and extension.
I
Check for oil leakage on welded or gland packing portions.
I
Check piston rod for cracks, deformation or other damage.
Replace if necessary.
Mounting Insulator and Rubber Parts
NLSU0011S02
I
Check cemented rubber-to-metal portion for separation or
cracks. Check rubber parts for deterioration.
Replace if necessary.
Thrust Bearing
NLSU0011S06
I
Check thrust bearing parts for abnormal noise or excessive
rattle in axial direction.
I
Replace if necessary.
Coil Spring
NLSU0011S03
I
Check for cracks, deformation or other damage. Replace if
necessary.
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FRONT SUSPENSION
Coil Spring and Shock Absorber (Cont’d)
SU-11
SFA508A
ASSEMBLY
NLSU0012
I
When installing coil spring on strut, it must be positioned as
shown in the figure at left.
SFA957A
I
When installing spring seat, make sure that it is positioned as
shown.
SSU035
Stabilizer Bar
REMOVAL AND INSTALLATION
NLSU0017
I
Remove stabilizer bar.
NFA053
I
When installing stabilizer, make sure clamp faces in correct
direction.
ARA027
I
Check stabilizer for deformation or cracks. Replace if neces-
sary.
I
Check rubber bushings for deterioration or cracks. Replace if
necessary.
I
Check ball joint can rotate in all directions. If movement is not
smooth and free, replace stabilizer bar connecting rod.
FRONT SUSPENSION
Coil Spring and Shock Absorber (Cont’d)
SU-12
SFA181A
Transverse Link and Lower Ball Joint
REMOVAL AND INSTALLATION
NLSU0018
1.
Remove wheel bearing lock nut.
2.
Remove tie-rod ball joint.
3.
Remove strut lower bracket fixing bolts and nuts.
4.
Separate drive shaft from knuckle by slightly tapping drive
shaft end.
Cover boots with shop towel so as not to damage them when
removing drive shaft.
SFA113AD
5.
Separate lower ball joint stud from knuckle with tool.
Refer to AX-5, “FRONT AXLE — Wheel Hub and Knuckle”.
YSU004
6.
Remove fixing bolts.
7.
Remove transverse link and lower ball joint.
8.
During installation, final tightening must be carried out at curb
weight with tires on the ground.
Tightening torque:
Refer to “FRONT SUSPENSION”, SU-10.
9.
After installation, check wheel alignment. Refer to “ON-VE-
HICLE SERVICE — Front Wheel Alignment”, SU-8.
INSPECTION
NLSU0019
Transverse Link
NLSU0019S01
I
Check transverse link for damage, cracks or deformation.
Replace it if necessary.
I
Check rubber bushing for damage, cracks and deformation.
Replace transverse link if necessary.
SFA858A
Lower Ball Joint
NLSU0019S02
I
Check ball joint for play. Replace transverse link assembly if
any of the following cases occur. Ball stud is worn, play in axial
direction is excessive or joint is hard to swing.
Before checking, turn ball joint at least 10 revolutions so that
ball joint is properly broken in.
Swinging force “A”:
(measuring point: cotter pin hole of ball stud):
7.8 - 82.4 N (0.8 - 8.4 kg, 1.8 - 18.5 lb)
Turning torque “B”:
0.50 - 4.90 N·m (5.1 - 50 kg-cm, 4.4 - 43.4 in-lb)
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FRONT SUSPENSION
Transverse Link and Lower Ball Joint
SU-13
Vertical end play “C”:
0 mm (0 in)
I
Check dust cover for damage. Replace it and cover clamp if
necessary.
FRONT SUSPENSION
Transverse Link and Lower Ball Joint (Cont’d)
SU-14
Service Data and Specifications (SDS)
GENERAL SPECIFICATIONS (FRONT)
=NLSU0020
Suspension type
Independent MacPherson strut
Shock absorber type
Double-acting hydraulic
Stabilizer bar
Standard equipment
FRONT WHEEL ALIGNMENT (UNLADEN*1)
NLSU0021
QG engine
YD engine
Camber
Degree minute (Decimal degree)
Minimum
−1°05
′
(−1.08°)
Nominal
−0°20
′
(−0.33°)
Maximum
0°25
′
(0.42°)
Left and right difference
45
′
(0.75°)
Caster
Degree minute (Decimal degree)
Minimum
2°04
′
(2.07°)
2°01
′
(2.02°)
Nominal
2°49
′
(2.82°)
2°46
′
(2.77°)
Maximum
3°34
′
(3.57°)
3°31
′
(3.52°)
Left and right difference
45
′
(0.75°)
Kingpin inclination
Degree minute (Decimal degree)
Minimum
13°40
′
(13.67°)
Nominal
14°25
′
(14.42°)
Maximum
15°10
′
(°15.17)
Total toe-in
Distance (A − B)
mm (in)
Minimum
1 (0.04)
Nominal
2 (0.08)
Maximum
3 (0.12)
Angle (left plus right)
Degree minute (Decimal degree)
Minimum
0°01
′
(0.02°)
Nominal
0°04
′
(0.07°)
Maximum
0°07
′
(0.12°)
Wheel turning angle
Full turn*2
Inside
Degree minute (Decimal degree)
Minimum
34°30
′
(34.50°)
Nominal
38°00
′
(38.00°)
Maximum
39°00
′
(39.00°)
Outside
Degree minute (Decimal degree)
Nominal
31°00
′
(31.00°)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with
engine idle.
*3: “Ground clearance up” model
LOWER BALL JOINT
NLSU0022
Swinging force “A”
(Measuring point: cotter pin hole of ball stud)
N (kg, lb)
7.8 - 82.4 (0.8 - 8.4, 1.8 - 18.5)
Turning torque “B”
N·m (kg-cm, in-lb)
0.50 - 4.90 (5.1 - 50.0, 4.4 - 43.4)
Vertical end play “C”
mm (in)
0 (0)
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FRONT SUSPENSION
Service Data and Specifications (SDS)
SU-15
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