Text preview for : en_4j2_2c.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno
Covers the 1.4L, 1.6L and 1.8L engine.
Year 2004
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SECTION : 2C
FRONT SUSPENSION
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2C2 General Specifications . . . . . . . . . . . . . . . . . . . . . 2C2 Fastener Tightening Specifications . . . . . . . . . . . 2C2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 2C3 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C5 Strut Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C5 Ball Joint and Knuckle . . . . . . . . . . . . . . . . . . . . . . 2C6 Excessive Friction Check . . . . . . . . . . . . . . . . . . . 2C6 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 2C7 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 2C7 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2C9 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2C9 Stabilizer Shaft and Insulators . . . . . . . . . . . . . . . 2C9 Stabilizer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C10 Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2C10 Hub and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 2C13 Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C14 Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C16 Crossmember Assembly . . . . . . . . . . . . . . . . . . . 2C18 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C21 Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C21 Control Arm Bushings . . . . . . . . . . . . . . . . . . . . . 2C21 Front Strut Assembly . . . . . . . . . . . . . . . . . . . . . . 2C22 Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C23 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C25 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 2C25
2C 2IFRONT SUSPENSION
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Center of Front Wheel to Bottom of Front Wheel Well Center of Rear Wheel to Bottom of Rear Wheel Well * CONDITION : Full Fuel in the Tank Trim Height 368 mm (14.4 in.) 367 mm (14.4 in.)
FASTENER TIGHTENING SPECIFICATIONS
Application Ball Joint Pinch Bolt Nut Ball JointtoControl Arm Nuts Front Control ArmtoCrossmember Bolt Rear Contral ArmtoCrossmember Bolt Crossmember LinktoCrossmember Bolt Crossmember LinktoTransaxle Bracket Nut Drive AxletoHub Caulking Nut Front CrossmembertoBody Bolts Piston Rod Nut Rear CrossmembertoBody Bolts Stabilizer LinktoStrut Assembly Nut Stabilizer ShafttoCrossmember Clamp Bolts Stabilizer ShafttoStabilizer Link Nut Steering KnuckletoStrut Assembly Nuts/Bolts Strut AssemblytoBody Nut NSm 60 100 125 110 114 169 300 130 75 196 47 25 47 120 65 LbFt 44 74 92 81 84 125 221 96 55 145 35 18 35 89 48 LbIn
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SPECIAL TOOLS
SPECIAL TOOLS TABLE
50020 Hex Nut
KM158 Remover/Installer
J366612 Forcing Screw
KM329A Spring Compressor
J37105B1 Support Bridge
KM507B Ball Joint Remover
J37105B3 Hub Adapter
J37105B2 Bearing Adapter
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2C 4IFRONT SUSPENSION
J42468 Front Strut Mount Nut Wrench
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DIAGNOSIS
STRUT DAMPENER
A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand than are shock absorbers.
Struts Seem Weak
Checks Check the tire pressures. Check the load conditions under which the vehicle is normally driven. Check the compression and rebound effectiveness of the strut dampener. Action Adjust the tire pressures to the specifications on the tire placard. Consult with the owner to confirm the owner's understanding of normal load conditions. Quickly push down and then lift up on the corner of the bumper nearest the strut dampener being tested. Compare the compression and rebound with those of a similar vehicle that has an acceptable ride quality. Replace the strut dampener, if needed.
Struts Are Noisy
Checks Check the mountings for looseness or damage. Check the compression and rebound effectiveness of the strut dampener. Action Tighten the strut dampener mounting nuts. Replace the strut dampener, if needed. Quickly push down and then lift up on the corner of the bumper nearest the strut dampener being tested. Compare the compression and rebound with those of a similar vehicle that has an acceptable ride quality. Replace the strut dampener, if needed.
Leaks
Checks Check for a slight trace of fluid. Check the integrity of the seal cover on the fully extended strut. Check for an excessive amount of fluid on the strut dampener. Action The strut dampener is OK. Replace the strut dampener. Replace the strut dampener.
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BALL JOINT AND KNUCKLE
Ball Joint Inspection
1. 2. 3. 4. 5. Raise the front of the vehicle to allow the front suspension to hang free. Grasp the tire at the top and the bottom. Move the top of the tire in an inandout motion. Look for any horizontal movement of the knuckle relative to the control arm. Ball joints must be replaced under the following conditions: S S S S S The joint is loose. The ball seal is cut. The ball stud is disconnected from the knuckle. The ball stud is loose at the knuckle. The ball stud can be twisted in its socket with finger pressure.
Another way to inspect the ball stud for wear is to check the fastener torque at the pinch nut. A loose nut can indicate a stressed stud or a hole in the knuckle boss. Worn or damaged ball joints and knuckles must be replaced.
EXCESSIVE FRICTION CHECK
Use the following procedure to check for excessive friction in the front suspension: 1. Enlist the help of another technician to lift up on the front bumper, raising the vehicle as high as possible. Slowly release the bumper, allowing the vehicle to assume its normal trim height. See "General Specifications" in this section. Measure the distance from the street level to the center of the bumper. Push down on the bumper, release slowly, and allow the vehicle to assume its normal trim height. Measure the distance from the street level to the center of the bumper. The difference between the two measurements should be less than 12.7 mm (0.5 inch). If the difference exceeds this limit, inspect the control arms, the struts, and the ball joints for damage or wear.
2.
3. 4. 5. 6.
Ball Stud Inspection
Make sure to check the tightness of the ball stud in the knuckle boss during each inspection of the ball joint. One way to inspect the ball stud for wear is to shake the wheel and feel for movement of the stud end at the knuckle boss.
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COMPONENT LOCATOR
FRONT SUSPENSION
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Cap Strut Upper Nut Piston Rod Nut Strut Mount Strut Bearing Washer Upper Spring Seat Front Spring Locator Upper Spring Insulator Hollow Bumper Front Coil Spring Lower Spring Insulator Front Strut Steering KnuckletoStrut Assembly Nut Steering Knuckle Brake Shield Front Hub Bearing 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Outer Snap Ring Front Hub Front Brake Disc Washer Caulking Nut Stabilizer Clamp Bolt Stabilizer Clamp Stabilizer Clamp Insulator Stabilizer Stabilizer Link Nut Stabilizer Link Front Suspension Crossmember Crossmember Cover Crossmember Cover Bolt Crossmember Bolt Crossmember Nut Control Arm Ball Joint
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MAINTENANCE AND REPAIR
ONVEHICLE SERVICE STABILIZER SHAFT AND INSULATORS
Removal Procedure
1. 2. 3. Raise and suitably support the vehicle. Remove the stabilizer shafttostabilizer link nut. Remove the crossmember. Refer to "Crossmember Assembly" in this section.
4. 5.
Remove the stabilizer shafttocrossmember clamp bolts. Remove the stabilizer shaft, the stabilizer shaft insulator clamp, and the insulators from the vehicle.
Installation Procedure
1. 2. Install the stabilizer shaft. Install the stabilizer shaft insulator clamps, the stabilizer shaft clamp bolt, and the insulators onto the crossmember. Do not tighten the bolt.
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3. Install the stabilizer link onto the stabilizer shaft and connect them with the stabilizer shafttostabilizer link nut.
Tighten
Tighten the stabilizer shafttostabilizer link nut to 47 NSm (35 lbft). S Tighten the stabilizer shafttocrossmember clamp bolts to 25 NSm (18 lbft). Install the front wheels. Refer to Section 2E, Tires and Wheels. S
4.
STABILIZER LINK
Removal Procedure
1. 2. 3. Remove the stabilizer shafttostabilizer link nut. Remove the stabilizer linktostrut assembly nut. Remove the stabilizer link.
Installation Procedure
1. 2. Install the stabilizer link. Install the stabilizer linktostrut assembly nut.
Tighten
Tighten the stabilizer linktostrut assembly nut to 47 NSm (35 lbft). 3. Install the stabilizer shafttostabilizer link nut.
Tighten
Tighten the stabilizer shafttostabilizer link nut to 47 NSm (35 lbft).
KNUCKLE ASSEMBLY
Tools Required KM507B Ball Joint Remover
Removal Procedure
1. 2. 3. Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. Remove the caulking nut from the axle shaft.
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4. Remove the brake caliper from the rotor. Support the caliper so it does not hang from the hydraulic brake hose. Refer to Section 4D, Front Disc Brakes. Remove the outer tie rod from the knuckle assembly. Refer to Section 6C, Power Steering Gear. On vehicles equipped with the antilock braking system (ABS), disconnect the ABS speed sensor electrical connection from the knuckle.
5. 6.
7.
Remove the ball joint pinch bolt and the nut.
8.
Separate the knuckle from the ball joint using the ball joint remover KM507B.
9.
Remove the nuts from the bolts that connect the knuckle assembly to the strut assembly.
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Notice : Do not over extend the axle joints. When either end of the shaft is disconnected, overextension of the joint can result in separation of internal components and possible joint failure. Use drive axle joint seal protectors whenever performing service on or near the drive axles. Failure to do so can cause internal joint or seal damage and result in possible joint failure. 10. Support the drive axle. 11. Separate the drive axle shaft from the wheel hub. 12. Remove the bolts that connect the knuckle assembly to the strut assembly. 13. Remove the knuckle assembly from the vehicle.
Installation Procedure
1. 2. Install the knuckle assembly onto the vehicle. Install the steering knuckletostrut assembly nuts.
Tighten
3. Tighten the steering knuckletostrut assembly nuts to 120 NSm (89 lbft). Connect the drive axle to the front wheel hub.
4. 5.
Connect the ball joint to the knuckle assembly. Install the ball joint pinch bolt and the nut.
Tighten
Tighten the ball joint pinch bolt nut to 60 NSm (44 lb ft).
6.
Connect the ABS speed sensor electrical connection.
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7. 8. 9. Connect the outer tie rod to the knuckle assembly. Refer to Section 6C, Power Steering Gear. Install the brake caliper onto the rotor. Refer to Section 4D, Front Disc Brakes. Install the caulking nut onto the axle shaft.
Tighten
Tighten the drive axletohub caulking nut to 150 NSm (111 lbft). Loosen the nut, then retighten it to 275 NSm (126 lbft). 10. Install the wheel. Refer to Section 2E, Tires and Wheels. 11. Lower the vehicle.
HUB AND BEARING
Tools Required 50020 Hex Nut J366612 Forcing Screw J37105B1 Support Bridge J37105B2 Bearing Adapter J377105B3 Hub Adapter
Removal Procedure
1. 2. 3. Remove the drive axle from the front wheel hub. Refer to "Knuckle Assembly" in this section. Remove the inner snap ring. Remove the wheel hub with the support bridge J37105B1, the hub adapter J377105B3, the hex nut 50020, and the forcing screw J366612.
4. 5.
Remove the brake shield. Refer to Section 4D, Front Disc Brakes. Remove the outer snap ring.
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6. Remove the wheel bearing with the support bridge J37105B1, the bearing adapter J37105B2, the hex nut 50020, and the forcing screw J366612. Clean the bore of the knuckle.
7.
Installation Procedure
1. Install the outer snap ring and push the wheel bearing into place with the support bridge J37105B1, the bearing adapter J37105B2, the hex nut 50020, and the forcing screw J366612.
2. 3. 4.
5.
Install the brake shield. Refer to Section 4D, Front Disc Brakes. Install the inner snap ring. Push the wheel hub into place with the hub adapter J37105B3, the bearing adapter J37105B2, the hex nut 50020, and the forcing screw J366612. Install the drive axle into the front wheel hub. Refer to Knuckle/Strut Assembly" in this section.
CONTROL ARM
Tools Required KM507B Ball Joint Remover
Removal Procedure
1. 2. 3. 4. Raise and suitably support the vehicle. Let the control arms hang free. Remove the wheel. Refer to Section 2E, Tires and Wheels. Remove the pinch bolt and the nut from the ball joint. In case of righthand side, remove the engine mounting.
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5. Disconnect the ball joint from the knuckle assembly using the ball joint remover KM507B.
6. 7.
Remove the control armtocrossmember bolts. Remove the control arm from the vehicle.
Installation Procedure
1. 2. Install the control arm. Install the control armtocrossmember bolts. Do not tighten the bolts.
3. 4.
Connect the ball joint to the steering knuckle. Install the ball joint pinch bolt and the nut.
Tighten
Tighten the ball joint pinch bolt nut to 60 NSm (44 lb ft).
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5. Install the control armtocrossmember bolts.
Tighten
Tighten the front control armtocrossmember bolt to 125 NSm (92 lbft). S Tighten the rear control armtocrossmember bolt to 110 NSm (81 lbft). Install the wheel. Refer to Section 2E, Tires and Wheels. Lower the vehicle. S
6. 7.
STRUT ASSEMBLY
Removal Procedure
1. Remove the strut upper cap and nut.
2. 3. 4.
5.
Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. On vehicles equipped with an antilock braking system (ABS), disconnect the ABS sensor line from the strut assembly. Remove the brake line from the securing bracket on the strut assembly.
6.
Disconnect the stabilizer shaft link by removing the stabilizer linktostrut assembly nut.
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7. Disconnect the steering knuckle by removing the steering knuckletostrut assembly nuts and the bolts.
8.
Remove the strut assembly.
Installation Procedure
1. Install the strut assembly.
2.
Connect the strut assembly to the steering knuckle by installing the steering knuckletostrut assembly nuts and the bolts.
Tighten
Tighten the steering knuckletostrut assembly nuts and the bolts to 120 NSm (89 lbft).
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3. Connect the stabilizer shaft link to the strut assembly by attaching the stabilizer linktostrut assembly nut.
Tighten
4. 5. Tighten the stabilizer linktostrut assembly nut to 47 NSm (35 lbft). Install the brake line to the securing bracket on the strut assembly. On vehicles equipped with the ABS, connect the ABS sensor line to the strut assembly.
6. 7. 8.
Install the wheel. Refer to Section 2E, Tires and Wheels. Lower the vehicle. Install the nuts securing the strut assembly to the body of the vehicle.
Tighten
Tighten the strut assemblytobody nuts to 65 NSm (48 lbft).
CROSSMEMBER ASSEMBLY
Removal Procedure
1. 2. 3. 4. 5. 6. 7. 8. 9. Raise and suitably support the vehicle. Remove the wheels. Refer to Section 2E, Tires and Wheels. Remove the nuts and bolts from the steering gear mounting bracket. Remove the return line bolt from the clip on the crossmember. Remove the exhaust pipe forward of the catalytic converter. Refer to Section 1G, Engine Exhaust. Disconnect the tie rod from the knuckle assembly. Refer to Section 6C, Power Steering Gear. Disconnect the ball joint from the knuckle assembly. Refer to "Knuckle Assembly" in this section. Disconnect the stabilizer link from the strut assembly. Refer to "Stabilizer Link" in this section. Remove the crossmember linktotransaxle bracket nut. 1) Remove the right lower engine mount. 2) Remove the rear transmission mount bracket.
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10. Remove the rear crossmembertobody bolts.
CAUTION : Two technicians must hold the front crossmember assembly and suitably support the assembly with a jack stand during removal of the front attachment bolts. Failure to support the front crossmember properly can result in personal injury. 11. Remove the front crossmembertobody bolts. 12. Remove the crossmember assembly from the vehicle.
Installation Procedure
1. 2. Install the crossmember assembly. Install the rear crossmembertobody bolts.
Tighten
Tighten the rear crossmembertobody bolts to 196 NSm (145 lbft). 3. Install the front crossmembertobody bolts.
Tighten
Tighten the front crossmembertobody bolts to 130 NSm (96 lbft). 4. 5. Install the bolts and nuts on the steering gear mounting brackets. Install the return line bolt into the clip on the crossmember. Refer to Section 6C, Power Steering Gear.
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6. Install the crossmember linktotransaxle bracket nut.
Tighten
Tighten the crossmember linktotransaxle bracket nut to 169 NSm (125 lbft). 7. Connect the stabilizer link to the strut assembly. Refer to "Stabilizer Link" in this section. 8. Connect the ball joint to the knuckle assembly. Refer to "Knuckle Assembly" in this section. 9. Connect the tie rod from the knuckle assembly. Refer to Section 6C, Power Steering Gear. 10. Install the exhaust pipe into the vehicle. Refer to Section 1G, Engine Exhaust. 11. Install the wheels. Refer to Section 2E, Tires and Wheels. 12. Lower the vehicle.
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UNIT REPAIR BALL JOINT
Disassembly Procedure
1. 2. 3. Remove the control arm. Refer to "Control Arm" in this section. Drill off the heads of the two rivets with a 12 mm (0.47 inch) drill bit. Punch out the rivets with a drift.
Assembly Procedure
1. Connect the ball joint to the control arm by inserting two ball joint bolts from below the control arm.
Tighten
2. Tighten the ball jointtocontrol arm nuts to 100 NSm (74 lbft). Install the control arm. Refer to "Control Arm" in this section.
CONTROL ARM BUSHINGS
Tools Required KM158 Remover/Installer
Disassembly Procedure
1. 2. Remove the control arm. Refer to "Control Arm" in this section. Remove the split sleeves from the rear control arm bushing.
3.
Press off the control arm rear damping bushing using a press and the remover/installer KM158.
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1. Press the control arm rear damping bushing into the control arm using a press and the remover/installer KM158.
2. 3.
Install the split sleeves into the rear control arm bushing. Install the control arm. Refer to "Control Arm" in this section.
FRONT STRUT ASSEMBLY
Tools Required KM329A Spring Compressor J42468 Front Strut Mount Nut Wrench
Disassembly Procedure
1. 2. Remove the strut assembly. Refer to "Strut Assembly" in this section. Fasten the strut assembly to the spring compressor (DW320010 or KM329A). Make sure the hooks are seated on the strut spring properly. Compress the front spring with the spring compressor. Use an open end wrench to hold the threaded piston rod while removing the piston rod nut and the washer with a commercially available double ring spanner, sharply offset.
3. 4.
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Important : Record the position of the front spring locator relative to the strut assemblytoknuckle bracket. Place the front spring locator back in the same position during assembly. 5. Remove the upper strut mount, the mount bearing, the upper spring seat, the upper ring insulator, and the hollow bumper. 6. Release the spring. 7. Remove the spring and the lower ring insulator.
Assembly Procedure
1. 2. 3. Install the lower ring insulator and the spring. Compress the spring using the spring compressor KM329A. Install the hollow bumper, the upper ring insulator, the front spring locator, the upper spring seat, the upper strut mount, and the mount bearing. Be sure the upper spring seat is clipped to the front spring locator.
4.
Install the piston rod nut.
Tighten
5. Tighten the piston rod nut to 75 NSm (55 lbft). Release the spring compresser KM329A
KNUCKLE
Disassembly Procedure
1. 2. 3. 4. Remove the knuckle assembly from the vehicle. Refer to "Knuckle Assembly" in this section. Remove the rotor. Refer to Section 4D, Front Disc Brakes. Remove the hub and bearing assembly. Refer to "Hub and Bearing" in this section. Remove the brake splash shield. Refer to Section 4D, Front Disc Brakes.
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1. 2. 3. 4. Install the brake splash shield. Refer to Section 4D, Front Disc Brakes. Install the hub and bearing assembly. Refer to "Hub and Bearing" in this section. Install the rotor. Refer to Section 4D, Front Disc Brakes. Install the knuckle assembly onto the vehicle. Refer to "Knuckle Assembly" in this section.
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GENERAL DESCRIPTION AND SYSTEM OPERATION
FRONT SUSPENSION
The front suspension for this vehicle is a combination of a strut assembly and a knuckle assembly. The strut assembly combines a strut dampener and spring mounted to the body of the vehicle. The upper end of the strut is isolated by a rubber mount and contains a bearing to allow the strut to turn. The knuckle is attached to the strut assembly and pivots on a ball joint bolted to the control arm. The control arms pivot from the body using rubber bushings. The ball joint is fastened to the steering knuckle with a pinch bolt and nut, and to the lower control arm with rivets. The stabilizer bar interconnects both strut assemblies of
the vehicle through the stabilizer link and is attached to the front suspension crossmember. Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel of the vehicle to stabilize body roll. When servicing the control armtobody attachment and the stabilizer shafttobody insulators, make sure the attaching bolts are loose until the control arms are moved to the trim height, which is curb height. Trim height is the normal position to which the control arms move when the vehicle is sitting on the ground. Refer to "General Specifications" in this section. The springs in the front suspension of engine family II are stronger and the strut dampeners heavier than are the springs and strut dampeners found in the front suspension of engine family I.
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