wheel Front suspenslon

240,260

Front wheel suspension

Contents
tuss
Specffications Spcial tooLs lllustrations l 2
Step

Group60: General
Wheel alignmen(

a t-A.21

Group61: Front wheel suspension

Beplacingsteering swivel ball joints: - eany proo, l a t p r o d .. . . , . , , , . , , , . Replacing strut upperjournal Rplacing controlarms and/or bushings Vehcle n railifi ........ .......... o Replacing front controlarm rear bushing: v s h i c l s orn i lh f t . . . . . . . . . a ..... ... - vehlcle floor on Replacingfronl shock absorbr R e p l a c rfn g n lc o i ls p r i n g. . . . . . . . . . . . . ro ll 19 23 28 33 36 40 46 B1-833 c1-412 D1 D2O E1 E2O F1-F10 H1 H25 r't-125

TP 30 000/ 1
45003.79 Printed USA in

Specifications

Specifications
l/Vheelalignment (unloadedcar)
(All Caster: carsupto and including 1978yearmodels) ..... 1979 year modelswith manual steering 1979 year modelswith powersieering Carroerset as nea' OPas poss,ote
Nng pin Inchnalionat 0o camber

+2o to +3o +2' to +3' 0 to +lo 12"

At2O.Ooturningof Turningangles outerwheel,innerwheelsho!d be turned2O.8o

Toe-in:
Ansle (2 d) Manual steering B b {mm) c-c {mm) 4.511.5 3.541 3.Ot 1.5 2.041 2.5!1 1.511

24 !a'
l6 t8'

All measurements made with the car unloaded. are The measurcments are iaken at hub heighl, as the angle measurement or the difference d, in mm between the front and rear edge of the wheels at points A, B or C (the tires wear thread inside shoulder or rim corner).

Ball ioints
lvlax. loadedfront end: axialplay with normally 1/8' (3 mm).

Tightening torques
N u t f o r c o n t r oa r m r e a rb u s h i n g . . . . . . . . . . . l . Bracketlor control arm rear bushing . . Fronr bo\ for conrol am bushing . . . .

Nm 5515 401r0 75!20 11 5 1 1 5 60t 10 2345 60t 10 20!5 60115 '120!20

ft. lbs. 40!4 29L7 54t 14 83:111 43!7 11!4 43!1 14!4 43!11 8719 Group 60 Genenl

B a l lj o r n r .r o c o n n o l a r 1 l . . . . . . B a l jl o i n tt o a t t a c h m e n t s l r u t . . . . . . . . . . . . . . . . . . . . . . . . . . . . or B a ' l j o r n ra a a c h m e a r o s r f l , l . , , Stee.ing rod to steeiag ar.n N u r sl o r u p o e r o u h a l h n g. . . . . . . . . . . . . t

Steering wheelnut

-[

Special tools

Specialtools
1801 Standard handle

2263 Puller
removing sleenng wheel

5045 Reiaining hook ior conirol arm when repiacno shock absorber pressing'n conro a'm rear bushing pressingoul/in conlrol arm rear bushing pre$ing in conrol arm rear blshng

5036| socket
shock aberber shafi nor

5037| Socket to retEinshock absorbershaft when rcmovins 5O3a Adjustrent tool 5039 spanmr shockabsorber on slrui nur (hydrau shockabsorber) ic 50401coil sprins h@k-uproot
removhg and installingcoil spring 5041 Coil spring compressor

pressinq controlarm fronl bushng in pressng out/in conrrol arm fronr bushng
pressng out con$ol arm fronl boshlng shock absorber nut on srrlr (gas pressureshock absobed

5043 I Pullr

o o

2263

5036 s037

o o

503I

Special tools

1ao1 504'l 5042 5043

v\
D IG
5084 5045 5091

'Ti h

Group60 Genenl

coil spring

i I
t:)

l-\

/@\

o o

Gtouo 60 Geneat

Group6O General
Checkingfront end for wear. Checkingand adjustingcamber, caster and toe-in
Special tools: 2263, 5038

AI

Raise the front end. Supporl under the control arms as near as possbe to

A2

Checksteeringrod ends,balljoints and steering linkage.

A3
Check wheel bearings, shock absorber bushing and upper attachmont or upper journalling {or

Check other side in the same way according to

A2-A3.

Gtoup 60 Genenl

A5

Check steering swivel ball joints for play. Check ball ioints for play wih, for example.a t re lever. Do noi damage the rlbber dusi cover. permssibe play s 3 mm. t\4axinrLrm

alignment turntables under front

Lower lront end and remove turntable catches,

AB

adjusttire pressure. Check, and i{ necessary,

Gtoup 60 General

Wheel alignment

A9

times. the Bounce lront end up anddown several

l l s m L s rb Eo o n e . o t h e t u , sre e c d m b ew r l l b e e r c e s s i v e h r sincethe convol alms do noi return to normal position cannot stand when frontend goesdown.lf the turntables srde forces, roll the car back a few feei, rhen forward agarn.

Ato

Install projectors. FolLow the nsiructionsfor equlpmentused. lf compensation for rim warp is made with front wheels raised. froni end mlst be bounced severaltimes 10 return to

Chck camber on botb Jront wheels. Corect camber:max.+1o, notto exceed1/2o difference beiween sides.Cambershould be as near 0p as possible in order to avoid shoulder wear on the tires.

check caster on both tront wheels. Correctcaster: +2o to +3o. Effective with 1979 models, casteron carswith power steering +3o to +4o. is lf Casier cannoibe adjusled. casterangleis incorrect, front end components must be checked.

t
Wheelalignment
Toe-in The toe in shouldbe set as follows:

At3

r /3"
Vehicle should be loaded. not tvteasuremenls be made must al center hub)heisht,d in an arcte, as readon certain insuumems. A, B and C reterro lire ooterdiamerer.tire inner shoutder and

A/4

To adjust, proceed as follows:

Bemove nuts on strut upperattachment.

Adjust camber:
Use lool 5038. Correctcamber:max.+1o. Max.O.50dfference between rghl and left wheels. Camber should be as near Oo as p o s s i b e1 0 a v o d s h o u d e rw e a r o n r i r e s .

Installand tighten nuts tor upperattachmems. Torque: 2Oa5 Nrn = 1414 ft.lbs.

GrouD60 General

Wheelalignment At7

Becheck casteron both Iront wheels. +2o to +3o

Effectivewilh 1979 models,caster on cars with power steering is +3o to +4o.

At8 Adjustingtoe-in: Loosen nuts,and lock toe-inwilh steering rods. adjust

Coriect toe in: se A13. Steeringrods must not differ more than 2 mm in length. lvleasu.ebetween wrerch gnp and Iocl nul.

at9 Tightennutsandspraythradswith rustproofing oil. A20

Check, and if necessary, adiust steeringwheel position.

pad pry Remove Carefully impact loose with screwdrivr. puller2263. steerins wheelwith No pulleris needed remove to steering wheelon 1979 year models.However, specialsocket (Volvo P/N a is io steering wheeL Pry nut. 1158146) requned remove wheelwith cover washer centerofsteering in screwdriver.

A2l

Installsteeringwheel. Torquei 60]15 Nm = 43111 ft.lbs.

Coai insul.iion pins with vaseline and press impact pad position. securelyinto Effeciivewhh 1979 models,a thin wallsocket,2T mm, is requlredto tighten the steeringwheel,

Steeing swivel

Group61 Frontwheel suspension

Replacing early prod. steeringswivel ball joints
Specialtools: 5036. 5037, 5039, 5040, 5043,5045, St73

BI

Supportfront end on stands. Place stands under frontjackattachmenrs.

t!4afkfront wheels to avoid rebalancing. Removefront wheels.

B2

Loosen shockabsorber retainingnut a coupleof tutns. (hydr.ulic) Usetoo 5039 for standard shock aDsorDer .nd 5173 for gas-pressure absorber. shock

B3

jack undercontrolarm.disconnect Place steering rod from steringarm.

Remove nut and detach rod with 5043.

Group6l

11

Steering swivel

Disconnectstabilizer bar from stabilizer link upperattachment.

,iiJ ,
V,lA

850

1B'

Bemove brake pipe bracket bolt.

B6

Remove protective cover oveJ shock absorber

nur,
Pry loose wilh screwdiver.

c
B7
LOOSen Oenternut. Loosen nurseveralturns 5036. Holdshockabsorber with plunserrod with 5037.

Gtuup 6 |

tz

Steeringswivel

B8

position Line-mark upperjournal andremovenuts.

Line-markover nut plate and wheel housing plate as il-

B9

o
Lowerjack and guideout springassembly. ro sqrng HooL wrrh assemblyshock absorber erarr'ng hook5045.

810

Usetool 5040 to compress spring.

Placethe two hook-uptools opposite eachother and with three spring between claws, the Compress coilsfree

Bl l

Remove centernut, lift oft upperiournal. with nut. shock absorber Use 5036to remove Hold tooL 5037.

f';:iil"", 13

Steeting swivel

l
Remove shock absorber retaining nut. Usetool 5039 for standard c) {hydrau shockabsorber and 5173 for gas presslreshockabsorber.

Bt3

v 4/

Pull up shockabsorber.

o
814

Loosen joint retaining bal' nut.

Loosena few turns untii ball joint bracketcomes loose. Use 19 mm socket. Use prpe wrench to hold on the weld.

815

Loosen balljointconicalpart trom strut assembly. Uselongbrass drift andhammer.

Gmup6l

Steering swivel

Bt6

Coat ins de of socket with vaselineor similar lubricant so nut may be lified when loose from ihread.

817

Hang up strut assemblY. Use steel wire to hang strut assemby to upper attachball jo nt from strut as ment. Bemovehook. Disconnect Do not stretch or damage brake hoses.

818

Disconnect ball joint from control arm,

D
819

Attach new ball joint to control arm. T o r q u e :1 5 1 1 5 N m = 8 3 1 1 1 i t l b s . 1 studcan grase from ballloinl.lf thrsis negecled, Clear belowst cks so tooftsr iniocone thatrubber betightened

Group 61

Steering swivel

820

Li{t strut assembly onto ball joint. Remove wre and hook up retaining hook 5045.

B2l

Install ball joint nut. Torque:60t1ONm = 4317 ft.lbs. Hold with pipe pliersaroundthe weld.

822

Install shock absorber and retaining nut. Tghten nut as muchas possible without turningstrut. Usetool 5039 for standard shockabsorber thydraulic) and tool 5173 for sas pressure shockabsorber.

823

Positionspring,rubberbumperand shock protection. absorber Turnspring that sprngcompressor so clawsfaceup.

Gtoup6l

Stee ng swivel

824

Installspring seat,upperjournal, washerandnut. Tighten wth 5036 andholdwith 5037. nut

Bemove springcompressor.
Loosensprng compressorbolts alternately,Make sure spnng ends seat correc|y rn upper and lower seats.

Guidstrut assemblyinto upperattachmenr wfieel housing.

Remove retaining hookand raisejack. Make resra su bitizer link s guidedinro position.

Turnjournalto correctpositionandtighten nuts.

Positon lolrnal according 10 tine-up marks. Torque: 2Ot5 Nm = 1444 ft.lbs.

Group 6l

Steeringswivel 828

rtainingnut. Tightenshockabsorber
Tlshten nui with 5036 and hold with 5037. Press protective cover into position.

829

0(

Tighten brake pipe bracket bolt.

o
830

Tightenstabilizr link to stabilizerbar.

o
83l

Tightensteeringrod to steeringarm. Torque: 6Ot1O Nm = 4317 ft.lbs.

Gtoup 61

18

Steeing swivel

Tightnshockabso.bernut in strut assembly. (hydraulic) aosoroer Usetool 5039 for standard shock andtool 5173 for gas-pressure absorber. shock

833

Installfront wheel. Uselhe marks madepreviously. Torque: 12Ot20 Nm = 87tg ft.lbs.

Replacinglate prod. steering swivel ball joint

Specialtools: 5039, 5173

CI

Supportfront ond on stands. Place stands under frontjackattachmenrs.

GtouD61 Frontwheet

19

Steeing swivel

c2

Remove front wheels. location avoidre-balancing. t!4ark to

c3

Q,(
Loosen shock absorber retaining nut a couple of tutns. shockabsorber Usetool 5039 for st.ndard(hydraulic) shockabsorberand 5173 for gas-pressure rt ry Onvehicles from 197I models is not necessa to loos retaining Theshockabsorber nut. en the shock absorber does not rest against ballloini attachment.

Ot

C4

Rsmovo four rotaining bolts for ball joint attachment. lf bots are secufed with lock washers, first pry these loosewith a screwdrlver.

Oisconnect ioint from controlarm. ball

Group61

C6

Bemove balljoint retaining nut.

Press ball joint out ot attachment.

Attach the new ball joint. Torque6Oa 10 Nm = 4317 fr bs. : Removegreasefrom ba joinr st!d. Olherwtseir can be tghtened loo far nto cone so rhat rubber be ow slcks Effclive from 1979 models wilh power sleering. batl loints are d fferenl for eft and righr sides.Compared1lr p r e v o u sy e a r s .b a l l l o i n i i s l o m m f o r w a r d i n c o n r r o l rod attachment.lt ts therforemost mportant rhar tnese ball loinls are nst.lled on corecr side

C9

- ---...-..---lillrlllli-

Attach ball joint to spring assembly. Usenew ock bolts.On vehlces equ pped w rh locKwasn ers lsee step C4), new lock washers mlst be !sed. P N 1229411. Torque: 315 Nm = l7t4 2 fl.lbs

Gtoup 6l

21

Steeiw swivel ball joints

cto

Tighten ball joint to control arm, Torque: 115415 Nm = 83111 ft.lbs.

ctl

Tightenshockabsorber relaining nulif previously loosened.

See Step C3.

c12

lnstall front wheels. Use markspreviously made. Torque: 120415 Nm = 8749 ft.lbs.

22

Group 61 Front wheel suspensidl

Sttut uwer jounal

Replacing strut upper journal

Specialtools: 5036, 5037, 5O4O,5043, 5045

DI

Supportfront end on stands.

Place stands under front jack attachments. [,4a* front wheels io avoid reba]ancing. Removefront wheels.

D2

Placejack undercontrolarm,disconnect steering rod trom steeringarm,

Remove nut and detach rod with 5043.

D3

Disconnect stabilizer trom stabilizerlink bar upperattachment.

Group61

23

Sttut upperjounal

tut

Bemovs brake pipe bncket bolt.

D5

Q,
Remove protective @ver over shock absorber nut. Pry loosewith screwdver. (

D6

LOOSen Center nut, Loosen severalturns 5036. Holdshockabsorber nut with plunger rod wlth 5037. (

D7

Line-markupper journal position and remove nuts, plate Line rnark overnut plate wheel and housing as il

24

Gtoup 6 |

Strut uwer jounal D8

Lower jack and guide out spring assembly. Hookspringassembly shockabsorber to wnh retaining hook 5045.

D9

Usetool 5040 to compress spring.

Place the two hook-up tools opposite each other and with threesping coilsfree betweenthe caws. Compress

Dto

Remove centernut, lift off upperjournal, Use 5036to remove Hold tool nut. shock with absorber 5037.

Dtl

journalassembly. Replace
For veh cleswirh 'einforcingrod (GTetct one bolt islonger

Group6 |

25

Strut upperJounal

Dt 2

Installupperjournal,washerand nut. Usetool 5036 to tighten Holdwith 5037. nut.

il
{}

Dt3

Remove springhook-up tool. Loosen Make spring seat alternately, sure ends correctly in upper lowerseats. and

D/4

into whel housing. Guidespringassembly Remove retaining hookandraise stabilizer iack.Guide

o(
I

Turnjournalto correctpositionand tighten nuts. journal previously. Position according linemark to made Torque: 2Ot5 Nm = 14t4 ft.lbs.

Group6l

20

lStrut upperlwrnal

Dt6

Tighten center nut and prss protctive into position.

Use tool 5036 to tighten and 5037 to hold.

0
Dt7

Tighten brake pipe bracket nut.

Dt8

link ro stabilizerbar. Tightenstabilizer

c
I
I
Tightensteeringrod to steeringarm. Iorquei 6Ot10 Nm = 4317 ft.lbs.

Group61

Controlams D20

tInstall front wheels. Use markspreviously made. Tdrque:120:t15 Nm = 87tg ft.lbs.

I
Replacing control arms and/or bushings
Vehicle on rail lift
Spectal tools: l8jl, 5081, 5082, 5083, 5084, 5085, 5091
(

Lift front end. Lifi underlack attachmentsuntil wheels almost lift from

E2

0(

Disconnect stabilizer Jromcontrcl arm. link

28

Gtoup6 |

rI
7-I

Controla ns

t
l-

I
Disconnect joint frcm @ntrol arm. ball

o o

E4

rearbushingbrackstfrom side Oisconnect memDer,

Rmove controlarm front rotainingbolt.

Remov controlarm. Remove bracket.

Gtoup61

29

E7

Press out control arm bushing. Using vce, place tool 5085 overco ar sideof bushing. Use lool 5091 to pressout bushing.

E8

0(
Press in control arm bushing. Place tool 5084 aoanst blsh ns collarside.presswrrh tool 5085 on reverse side.

E9

Pressout controlarm bracketbushing,

Pace tool 5082 under brackel. Pressout bushingwith tool 5083 and h.nde 1401.

Eto
Install new bushing in brackt. veh weredifferent righrside for On earlier cles, bushings {sofi)andleft sde (hard)tomakethe car lesssensitive Ths couldin criaincases res'r In steering t wheelvr bralions duringbrakingHardbushings now usedon are
1205826-9 1221942-O

0(

P,/N 1205826-9 Soft bushing P/N 12219a2 0 Hard bushing

30

Gtoup 6l

Controlarms

Etl

Pressin controlarm brackotbushing.

Placetool 5081 against bushing collar side. Press on bracket with tool 5082 and handle 1901.

Et2

Attach bracketto controlarm,

Installbracket, washer and nut. Do not tighten nut harder lhan washer can be turned by finger force.

Et3

Attach contrcl arm. Insta front rctaining I bolt without tighiening nut.

Guide stabilizerlink into position. Tighten ball joint to controlarm. T o r q u e : 5 1 1 5N m = 83111 ft.lbs. 11

Gtoup 6 |

5l

Attach bushingrar bracketto side member. Torque: 40110 Nm = 2917 ft.lbs.

Tightenstabilizer link to controlarm,

Et7

Lower front end.

Roll caf back and forth while bouncingit up and down severaltimes to let control arms lake up normal position.

Et8 Tightenbushingrear nut. Tofque5515 Nm = 4Ot4 ft.lbs.

BFplac,ng r.ghrsrdebush,ngs ve'1ictes on wth B2 1 engine: To tighten nut, disconnectexhaustpipe from flange and attachment.lnstall new gasket when rcconnectingex-

32

Group6l

Controlarms

Tightn front bushing boll. Torque 75120 Nm = 54415 ft.lbs.

Replacing front control arm rear bushing

Vehicleon rail lift
Specialtools: l8Ol, 5O8l, 5082, 5083

Disconnect rgar bushingbracketfrom side memDef.

Removebrackei Irom control arm. Remove andbracket nut from control arm.

Group61

33

Controlatms F3

Pressout controlarm bracketbushing. Place 5082 under tool brackei. Press bushinq out wirh tool5083 andhandle 1aO1.

Installnew bushingin bracket.

On earlier cles, veh bushings weredlfferent rightside for boft) and left sde (hard)tomakethe car lesssensitive This coud in certaincasesresultin steering wheelvi brations durlngbraking. Hardbushlngs now usedon are
12058269 12219420

P/N 1205826 Soft bushins 9 P/N I221982O Hardbushing

F5

Pressin controlarm bracktbushing.

Place tool 5ogl againsl bushing collar side. Press on bracket with tool 5082 and handle 1901.

F6

Attach bracketto controlarm.

nstallbracket,washer and nut. Do not tighten nui harder lhan washer can be turned by finger force.

Group6l

Conttulams

Attach bushingrearbracketto side mmber.

40a1ONm = 2947 ft.lbs.

0
Bounce lront end.

F8

Bouncefrontend up and down severaltrmestolet control arms iake up normal positron.

F9 Tightenbushingrear nut. Torque: 55i5 Nm = 4Ot4 it.lbs.

Fto
with 821 engine: Replacing right sidebushingson vehicles To tighten n!i, disconnectexhaustpipe from flange and dtrach-err. Insrall rEw gaskel wher reconreLl.ng er

Group6l

?E

Conttul ams

Replacing control arm rear bushing

Vehicle on tloor Specialtools: 5081,5082,5OA3 l8ol,

Mesure distancebetweenfenderdgeand hub @mer,

Before li{ting car from floor. Ivleasur both sides if on both bushingsare to be replaced.

G2

Placefront end on stands. Place stands under frontiackattachments.

G3

o( o(

Disconnect stabilizer links t.om control arms. Disconnecl bothsidesevenif onlyone bushing reon is placed. reason lsttheconlrol The isto arms takeupcorrecl position whenlightening.

36

Group6l

righrside bushngs on veh cles w th 821 When replacinq eng nes. d sconnectexhaust pipe irom f ange and front

-*

Disconnect bracket Irom side member and control arm,

G6

Press out control arm bracket bushing. Prss bushing out with Pacetool 5082 underbrackel. tool 5083 and hande1401.

I
Install new bushing in bracket.

G7

vehrcles. bushrngs weredifferent nght sde for On earlier (soit)and side(hard)io eft makethe car lesssensitve This couldln cerrain casesresuh n steenngwhee vrbratonsduringbrakifg.Hardb(rshlngs now lsed on are
1205a26 9 1221942A

P, N 1205826-9 Soft bushing N P.i 1221982 Hardbushlns O

Group6l

Contrcl arms G8

Pressin controlarm bracketbushing.

Place lool 5081 against bushing collar side. Press on bracket wth tool 5082 and handle 1801.

G9

Attach bracketto controlarm.

lnstallbracket, washer and nut. Do not tighten nut harder than washer can be turned by finger force.

G/O

Tightenbracketto side member. Torque: 40t10 Nm = 2917 ft.lbs

Gtl

Loadtront springsto let control arms lake up normaloosition.

Removestandsfrom jack attachments.Placejack as far Low out as possible undercontro 6rrn with new bushinger car so that it rests on stand and wheel on other side.

38

Gtwp 6l suspmsion

Measure distance between {ender edge and hub Bo!nce c.r severa t mes and measure stance. t sho!Ld d b e s a m ea s n S t e p G l . NOTE O n e s i d eo n w h e e ! o n e s d e o r s t a n dw i l l . naccuracyand is necessary be ab e 1o to

0
Tighten rear bushing. Torque: 5515 Nm = 4014 fi. bs. Raise againand plt t on two stands. car

Gt4

NOTE W h e n r e p a cn g r g h l s d e b u s h i n g o n v e h i c l e w r h 8 2 1 s s ngine,instal new flange gasket.Attach exhaustpipe 10 ilange and front aitachmenr

Tighten stabilizer links on both sides.

Gtoup 6l

?q

Front shock absotber

Replacing front shock absorber

Specialtools:5036, 5037, 5039. 5O4O,5043, 5045, 5173

Raise front end. Jack up front end. Placestands under front jack attachMark wheel location to avoid rebalancing. Remove

H2

Loosen shock absorber retaining nut on strut assembly. Loosen a coupleofturns. tool5039 for standard nut Use (hydraulic) shockabsorbers 5173 for gas-pressure and

H3

Disconnect steeringrod from steeringarm, jack Place undercontrol Remove Usetool arm nui. 5043
to disconnectsteering rod.

40

Gtoup6l

Frontshockabsoher

from upperlinkattachment. stabilizer Disconnect

H5

Remove bolt for brakepipebracket.

H6

|||ilrh,

Bemoveprotective cover over center nut Pryloose with screwdriver.

Loosen shockabsorber retainingnut.

Loosennui severalturns.Use tool 5036 and hold shock absorber plunser rod wnh 5037.

Otoup 6l

41

Frcnl shockabsort)er H8

Upperjournal.
Lrnernark over nur plate and wheel housing ptate. Re-

H9

Strut.
Lower jack and guide out strut assembly.Hook it Into stab izer wirh rerainingtoo 5045.

Hto

Spring.
Attach spring hook-up toos oppositeeach oiher. Three spring coLs free between claws. Compressalternately.

Ol

Upper journal. n Use tool5035 to rernove center ut.Holdshock absorber wnh 5O37.Remove upperjournal, spring seatand rubbef

42

Group6l

r
\_r/ '1 Pull up shock absorber

Front shock absorbel

Ht2

Remove shock absorbr retaining nut, (hydraullc) Usetoo 5039 for standard shockabsorber and 5173 for gas-pressure shockabsorber

Insert new shock absorber,

Tghien nli as muchas possible withoui tlrnLngstrut. Usetool 5039 for standard shockabsorber hydraulic) and 5173 for gaspressure shockabsorber.

Installspring, rubber damper and shock absorber ptotecton. Turn springso that sprng hook-up tool cbws face up.

Gtoup 6l

43

Frcnt shockabsofuel Ht6

Installspring seat,upperjournal, washerand nut. Usetool 5036 ro tighlen and 5037 to hold.

Bemovespringhook-up tool.
Loosentool alternately.Make sure sprlng ends position correclly in upper and lower seats.

Ht8

Guidestrut assembly into wheel housing.

Removeretaininghook. Raisejack. Make sure siabilizer link guides inro position,

Ht9

Installjournal.
Positionjournal according to line-marks.Tighlen nuts. Torque 2Ot5 Nm = 1414 ft.lbs.

Group6l

Front shock absorbel

Tighten cnter nut. proUsetool 5036 to tightenand 5037 to hold.Press tectivecoverinto position,

H2l

Tightenbrakepipe bracket.

H22

Tightenstabilizer link to bar.

H23

Tightenstoeringrod to steringarm. Torquer 6Ot10 Nm = 4317 ft.lbs.

Group6l

45

H24

Tightenshockabsorber on strut assembly. nut (hydraulic) absorber Use too 5039 for standard shock and 5173 for gas-pressure absorber. shock

H25

Install front wheel. previously Use markings, made. Torqus 'l20i 20 Nm = 87tg ft.lbs.

Replacing front coil spring

Il

Raise front end.

Jack up, place slands under fronl jack attachments. Ma* locationof front wheels to avoid re balancing.Re-

46

Gtoup 6l

I2

Placejack under control arm as support,

I3

steeringrod from steeringarm. Disconnect Usetool 5043.

I4

Disconnect stabilizer {rom link.

I5

Remove bolt for brake pipe bracket.

Gtoup 6l

47

I6

protectivecovorover center nut Remdve

Pry loose wlih screwdriver.

I7

Loosen center nut. Loosen several tums. Use tool 5036 and hold shock plunger wlih 5037. absorber

IB

Upper journal. Line-mark acrossnut plate and wheel housingplate.

I9

Disconnect strut. Lowerjack and guide out strui assembly. Hook stnrt assembly stabilizer to wirh retaining hook 5045.

48

Group 6l Frcntwheel suspension

I to

Springl Three Attachspringhookup roolsopposite eachother. springcoilsfree betweenclaws.Compress allernately.

111

UpperJournal:
Usetool5036io removecenlernut. Holdshocksbsorber spnngseatand rubber wLrh5037. Bemoveupperjournal,

I t2

Compress spring. Usespring compressor 5041 and mpactgun.

r t3

Freespring. tool spring comFirsl remove spring hook-up 5040,then pressor 5O41.

Gtoup 6l

49

I t4

Compress new spring,

Use sprng compressor 5O4l and impact gun.

I t5

Install spring hook-up tool. Place springhookup tools 5040 opposire eacnorne.. Threefree springcoib between claws.Compress alrernately.Remove springcompressor 5041.

176

Installspring.
Tlrn spring so compressorcaws face up. Insrattrlbber bumper .nd dust cover.

I t7

Installjournal. lnsiaI sprng seat.upperjournal, washerand nut. Use lool 5036 to tightenand 5037 to hold.

50

Gtoup 61

I t8

Remove springhook-uptool. ends Make sprang positron Loosen alternately. sLrre tool in andlowerseats. corrccrly upper

into whel housing. Guidestrut assembly jack. Remove retaining Raise Make ftat stabhook. sure inlo ilizer guides position. link

t20

Installjournal. journal to Tighten nuts. Position according line-marks. Torqus2Ot5 Nm = 1414 ft.lbs.

I 2l

Tightencente. nut. proPress tool and Use 5036 to tighien 5037 to hold.
tective cover into Positron.

Gtoup 6 | suspension

122

Tighten brake pipe bracket.

123

Tighten stabilizer link to bar.

124

Tighten steering rod to steering arm. Torque: 60410 Nm = 4317 ft.bs.

lnstalltront wheel.
Use markings,prevously made. Torqle: 120:t2O Nm = 8719 ft. bs

Group6l suspension

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