E suspension
RSU Rear suspension
Notes on work .................................................. .. ...... 2
·Caution .................................................. ................ Two
Prepared by .................................................. .................. Three
Special tools .................................................. ... ...... 3
Rear suspension ASSY .................................... 4
·Diagram .................................................. ............. Four
And inspection of on-board, maintenance ......................................... Five
And inspection of the wheel alignment ..................... . . . . . .Five
shock absorber ........................................... Eight
And removal, installation ......................................... Eight
Disassembly, assembly ................................................ Eight
Suspension arm ........................................... Nine
·removal .................................................. ... ...... 9
·attachment .................................................. ... . . . . Ten
Radius rod ................................................ . . . . 11
·removal .................................................. ... . . . . 11
And inspection after removal ....................................... . . . . 11
·attachment .................................................. ... . . . . 11
RSU - 1
Front lower link ............................................ Twelve
·removal .................................................. ...... Twelve
And inspection after removal .......................................... Twelve C
·attachment .................................................. ...... Twelve
Rear lower link and coil spring ............... 13
·removal .................................................. ...... 13
And inspection after removal .......................................... 13
D
·attachment .................................................. ...... 14
stabilizer ................................................ . . . 15
·removal .................................................. ...... Fifteen
And inspection after removal .......................................... Fifteen
·attachment .................................................. ...... Fifteen RSU
Rear suspension member ............................. Sixteen
And removal, installation ................................... . . . 16
Service data ................................................ . . . 17
Wheel alignment .................................. 17
Ball joint .......................................... 17 F
With-tightening torque ................................................. . . . 17
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 Notes on work

Notes on work PFP: 00001

Caution JES002SL

• The final tightening of the bushes is, after the vehicle ground, carried out in the empty state. Also be sure that Nikki wipe because adhesion of oil to please the low durability of the rubber

bushes.

• The empty state, the fuel packed, cooling water and lubricating oil are defined amount of state. However, spare tire, jack, onboard the tool is that you in a state of
down from the vehicle.

• When you develop a suspension parts, be sure to check the wheel alignment.

• Kashimenatto because of the re-use of non-parts, to replace it with a new one at the time of installation. Although at the time of new are coated with oil, to perform the fastening in a state in which

with the oil of that.

RSU - 2
 Prepared by

Prepared by PFP: 00002

Special tool JES002SM

name Use

B
Preload gauge
Ball joint week dynamic torque inspection
ST3127 S000

ZZA0806D

RSU

KA

RSU - 3
 Rear suspension ASSY

Rear suspension ASSY PFP: 55020

Diagram JES002SN

SEIA0177J

1. Bush 2. Mount seal 3. Distance tube

Four. Mount bracket Five. Bound bumper cover 6. Bound bumper

RSU - 4
 Rear suspension ASSY

7. shock absorber 8. Axle 9. Cotter pin

Ten. Upper sheet 11. coil spring 12. Rubber sheet

13. Rear lower link 14. Front lower link 15. Radius rod

16. Suspension arm 17. Connecting rod mount bra 18. Connecting rod
Ket

19. Def mount stopper 20. Rear suspension member twenty one. stabilizer

twenty two. Bush twenty three. Clamp twenty four. Members stay

Inspection of on-board, maintenance JES002SO

Mounted state of each component (loose, play, etc.) and the components of the state (wear, damage, etc.) to check whether or not there is an abnormality in.

Inspection of the shock absorber

C
• Oil leakage of the shock absorber, to check whether there is any damage to the damage and the attachment portion.

Inspection of wheel alignment JES002SP

Overview D
• Wheel alignment is measured in empty state. The empty state, the fuel packed, cooling water and lubricating oil are defined amount of state. However, spare tire,
jack, automotive tools, keep the state that was down from the vehicle.

Work before inspection

RSU
1. To check the air pressure and tire wear.

2. To check the deflection of the load wheel.

3. To check the axial end play of the wheel bearings.

F
Four. To check the operating state of the shock absorber.

Five. Loose in axle and suspension each mounting portion, to check whether the deformation is not.

6. Each link, damage to the arm and members, crack, to check whether or not there is deformation and the like.
G
7. Vehicle attitude is normal or inspection.

Camber inspection

Quick if you use an alignment gauge reference: • Rear wheel alignment inspection can accurately a short period of time in the inspection by using the H
quick alignment gauge.

• Quick For detailed handling point of alignment gauge, refer to the instruction manual.

1. Place the rear wheel on the turning radius gauge, the front wheel is turning Raj A

To level the vehicle is placed on the same height of the table and Sugeji. I

MAA0273D

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RSU - 5
 Rear suspension ASSY

2. Quick alignment gauge body up arrow stickers as in the figure is the

The measure is set perpendicular to the floor face to face.

Reference value

Camber Highway Star - 0 ° Twenty '± Thirty '

Except Highway Star - 0 ° 05 '± Thirty '

MAA0551D

3. If the measured value is out of the reference value, A of the front lower link

It is adjusted in the adjustment bolt.

Caution : After camber adjustment is possible to perform sure toe inspection.

SEIA0180J

Toe-in inspection

Quick If you use the alignment gauge

1. Quick Place the alignment gauge body on top of the surface plate, jig block

Using the toe angle measurement for the level 0 ° To adjust to.

2. Measuring wheel to quick alignment gauge the body of the arrow sticker straight

Proceed to set so as to face in the direction.

MAA0552D

3. Those close to the center line in the front wheel nut of the measurement site One Pieces outside

And, to set the hub bolt adapter.

Four. The connecting bar is set in the vehicle.

Caution : As connecting bar and the vehicle are parallel, considering tread,

A, B Possible to adjust the distance.

Five. Quick Remove the alignment gauge body from the vehicle, on top of the surface plate

Place was measured, and converts the measured value to the normal value in the following conversion equation.

MAA0554D
Sin {measured value　note) ( Ten Ary)} × tire outer diameter ( mm ) = Toe-in ( mm ) Note) indicates the sum of the

measured values ​of the left and right wheels and the measured values ​here. Calculation example measured

value 0 ° Thirty '( 0.5 °) the outer diameter of the tire 600mm in the case of

Sin0.5 × 600 = 5.2mm

RSU - 6
 Rear suspension ASSY

Reference value

Toe-Highway Star In 6mm ~ 0mm

Highway Star except in 4mm ~ Out 2mm

6. If the measured value is out of the reference value, of the rear lower link adjuster

It is adjusted in the Toboruto. B

Caution : If you want to adjust the adjustment bolt is, be done right and left the same amount.

SEIA0181J

RSU

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RSU - 7
 shock absorber

shock absorber PFP: 56210

Removal, installation JES002SQ

removal

1. Remove the tire from the vehicle.

2. Set the jack to the axle.

3. Remove the lower mounting bolt and nut shock absorber.

Four. The jack removed from the axle.

Five. Remove the shock absorber upper mount bracket mounting nut, remove the shock absorber from the vehicle.

Inspection after removal

• Deformation in shock absorber, crack, damage, and check whether or not there is, if there is an abnormality, replace.

• Damage to the piston rod, uneven wear, check that there is no such as bending, if there is an abnormality, replace.

• Check that there is no oil leakage from the weld and seal part, if there is an abnormality, replace.

attachment
• "Rear suspension for each tightening torque, etc. ASSY " " Diagram"( RSU-4 page ) Refers to the, carried out in the reverse procedure of removal.

Caution : Look at the diagram, re unusable parts must not be re-used.

• Tightening of the shock absorber under the side of the mounting bolt and nut is carried out in empty ground state, carry out the inspection of wheel alignment. " Inspection of
wheel alignment "( RSU-5 page ) See you confirm that you have read.

Disassembly, assembly JES002SR

Disassembly

Caution : When removing components from the shock absorber, this is not to scratch the piston rod of the shock absorber

When.

1. Remove from the mount bracket to mount seal.

2. The shock absorber winding the cloth to shock absorber under side is set in the vise.

Caution : That it does not set the vise to the cylindrical portion of the shock absorber.

3. So that the piston rod does not rotate, to secure the front end of the piston rod, loosen the piston rod lock nut.

Four. Bush, distance tube, mount bracket, the bound bumper cover and bound bumper shot
Remove than click absorber.

Inspection after decomposition

Bound bumper and Bush

• Cracks in the bound bumper and the bush, and inspect it for damage, if there is an abnormality, replace.

assembly
• "Rear suspension for each tightening torque, etc. ASSY " " Diagram"( RSU-4 page ) Refers to the, carried out in the reverse the removal procedure.

Caution : • Look at the diagram, re unusable parts must not be re-used.

• When installing each component to shock absorber, Ikoto such scratch the piston rod of the shock absorber.

• It performs a final tightening of each part in the empty ground state, carry out the inspection of wheel alignment. " Inspection of wheel alignment "
(RSU-5 page ) See you confirm that you have read.

RSU - 8
 Suspension arm

Suspension arm PFP: 55501

removal JES002SS

1. Remove the tire from the vehicle.

2. Remove the drive shaft. "Rear drive shaft" " Removal, installation "( RAX-8 page ) See you confirm that you have read.

3. Remove the mounting nut, remove the connecting rod mount bracket than suspension arm. B

Four. Set the jack to the rear lower link.

Five. Remove the shock absorber. "shock absorber" " Removal, installation " (RSU-8 page) See you confirm that you have read.

6. Remove the cotter pin of the suspension arm ball joints, remove the nut. C

7. Using a ball joint remover (general-purpose tool), Do not care so as not to damage the boot of the ball joint
The reluctant suspension arm removed from the axle.

Caution : Since the threads of the damage prevention and the ball joint remover (general-purpose tool) is likely to come off sharply, lock
D
That tacked a nut.

8. Remove the mounting bolt and nut of the suspension arm and rear suspension members.

9. From a vehicle, remove the suspension arm.

RSU
Inspection after removal

Visual inspection

• Suspension arm and Bush to deformation, cracks, and inspect for any damage, etc., the suspension arm is if there is an abnormality ASSY In exchange.

• Cracks in the ball joint of boots, damage, if you check whether there is any leakage, etc. of grease, there is an abnormality, the suspension arm ASSY In exchange.

Inspection of the ball joint

G
• Move the ball stud by hand, it is not caught, etc., to check whether the smooth motion.

Yo dynamic torque inspection

Caution : Before measurement Ten Move by hand more than once, it has done from the warmer the ball joint.

• Multiplied by the spring balance to the cotter pin mounting holes, the measured value of the spring balance is to H

check whether there within the reference value when the ball stud began to move.

Reference value

Yo dynamic torque: 0.5 ~ 3.4N - m { 0.06 ~ 0.34kg - m } Measure of the spring

balance: 7.9 ~ 54N { 0.81 ~ 5.5kg } I

• When departing from the reference value, the suspension arm ASSY In exchange.

FAC1020D J

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RSU - 9
 Suspension arm

Week dynamic torque inspection

• Attach the nut to the ball stud, using the pre-load gauge (special tool), to check whether the
sliding torque is within the reference value.

Reference value

Week dynamic torque: 0.5 ~ 3.4N - m { 0.06 ~ 0.34kg - m }

• When departing from the reference value, the suspension arm ASSY In exchange.

FAC1021D

Axial end play inspection

• Press the tip of the ball joint in the axial direction, check that there is no backlash.

Reference value

The axial end play: 0mm

• If there is a backlash, suspension arm ASSY In the conversion.

attachment JES002SU

• "Rear suspension for each tightening torque, etc. ASSY " " Diagram"( RSU-4 page ) Refers to the, carried out in the reverse procedure of removal.

Caution : Look at the diagram, re unusable parts must not be re-used.

• It performs a final tightening of each part in the empty ground state, carry out the inspection of wheel alignment. " Inspection of wheel alignment "
(RSU-5 page ) See you confirm that you have read.

RSU - 10
 Radius rod

Radius rod PFP: 55110

removal JES002SV

1. Remove the tire from the vehicle.

2. Set the jack to the axle.

3. Remove the body-side mounting bolts of the members stay. B

Four. Loosen the rear suspension member side mounting nut of the members stay, the members stay in the free state.

Five. Remove the mounting bolts of the rear suspension member and the radius rod.

6. Remove the mounting bolt and nut of the radius rod and the axle. C

7. The radius rod removed from the vehicle.

Inspection after removal JES002SW

• Radius rod and variations in the bush, crack, inspect it for damage, if there is an abnormality, replace the radius rod. D

attachment JES002SX

• "Rear suspension for each tightening torque, etc. ASSY " " Diagram"( RSU-4 page ) Refers to the, carried out in the reverse the removal procedure.

RSU
Caution : Look at the diagram, re unusable parts must not be re-used.

• It performs a final tightening of each part in the empty ground state, carry out the inspection of wheel alignment. " Inspection of wheel alignment "
(RSU-5 page ) See you confirm that you have read.

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RSU - 11
 Front lower link

Front lower link PFP: 55110

removal JES002SY

1. Remove the tire from the vehicle.

2. Set the jack to the rear lower link.

3. Remove the mounting bolts and nuts of the front lower link and the rear suspension members.

Four. Remove the lower mounting bolts and nuts of the front lower link and shock absorber.

Five. Remove the mounting bolts and nuts of the front lower link and the axle

6. The front lower link removed from the vehicle.

Inspection after removal JES002SZ

• Deformation in the front lower link and the bush, crack, inspect for any damage, etc., to replace the front lower link if there is an abnormality.

attachment JES002T0

• "Rear suspension for each tightening torque, etc. ASSY " " Diagram"( RSU-4 page ) Refers to the, carried out in the reverse the removal procedure.

Caution : Look at the diagram, re unusable parts must not be re-used.

• It performs a final tightening of each part in the empty ground state, carry out the inspection of wheel alignment. " Inspection of wheel alignment "
(RSU-5 page ) See you confirm that you have read.

RSU - 12
 Rear lower link and coil spring

Rear lower link and coil spring PFP: 551B0

removal JES002T1

1. Remove the tire from the vehicle.

2. Remove the brake caliper, keep hanging to a place that does not interfere with the brake caliper. " Caliper A SSY
Removal of, mounting "( BR-33 page ) See you confirm that you have read.
B
Caution : While it is removing the brake caliper, that you do not step on the brake pedal.

3. Set the jack to the rear lower link.

Caution : Jack be firmly set so as not to deviate from the rear lower link.

C
Four. Off the members stay loosen the rear suspension member side of the mounting nut to remove the members stay body-side mounting bolts

To Lee state.

Five. Remove the radius rod Remove the mounting bolt from the rear suspension members.

6. The mounting bolts and shock absorber lower Remove the nut removed from the front lower link. D

7. Set the spring compressor (general-purpose tool) to the coil spring

It was collected, to compress the coil spring.

Caution : Spring compressor to the coil spring (general-purpose tool)

Make sure that you have attached securely, to perform the compression of RSU
the coil spring.

8. Rear suspension member side mounting bolts of the rear lower link, nuts
Loosen the door, remove the axle side mounting bolt, a nut.
F
9. Slowly lower the jack, upper sheet, and coil spring
A rubber sheet removed from the rear lower link.
SEIA0182J

Caution : Connecting the coil springs and shock absorbers with a wire for the spring is likely to come off suddenly
To put in.
G
Ten. Loosen gradually the spring compressor (general-purpose tool), spring compressor (General Engineering from the coil spring
Remove the ingredients).

Caution : In the mounting position of the coil spring, loosening it while checking so that displacement does not occur.

11. Rear suspension member side mounting bolts, remove the nut, remove from the vehicle the rear lower link. H

Inspection after removal JES002T2

• Rear lower link and the bush, deformation in the coil spring or the like, crack, inspect for any damage, etc., if there is an abnormality, replace the rear lower link
and coil spring or the like.
I

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RSU - 13
 Rear lower link and coil spring

attachment JES002T3

• "Rear suspension for each tightening torque, etc. ASSY " " Diagram "
(RSU-4 page ) Refers to the, carried out in the reverse the removal procedure.

Caution : Look at the diagram, re unusable parts must not be re-used.

• Check that the upper sheet is attached as shown in the figure.

Caution : Claws of the vehicle body-side bracket as upper sheet Figure ( Three Months

Tokoro) and that you fit in advance ensure that inside the protrusion of the upper sheet.

• It is carried out with Ri taken to align the groove of the recess and the rear lower link of the rubber
sheet.

Caution : Be careful at the top and bottom of the spring. Up and down the identification paint

Judges that Ri.

• It performs a final tightening of each part in the empty ground state, carry out the inspection of wheel

alignment. " Inspection of wheel alignment "( RSU-5 page ) See you confirm that you have read.

SEIA0187J

RSU - 14
 stabilizer

stabilizer PFP: 56230

removal JES002T4

1. Remove the tire from the vehicle.

2. Remove the mounting nut, remove the connecting rod mount bracket than suspension arm.

3. Remove the connecting rod lower mounting nut, remove the connecting rod from stabilizer. B

Four. Remove the clamp mounting bolts, remove the stabilizer from the vehicle.

Inspection after removal JES002T5

• Stabilizer, bush, clamp, connecting rod, deformed into a connecting rod mount bracket, crack, inspect for any damage, etc., if there is an C
abnormality, replace.

attachment JES002T6

• "Rear suspension for each tightening torque, etc. ASSY " " Diagram"( RSU-4 page ) Refers to the, carried out in the reverse the removal procedure.
D

Caution : Look at the diagram, re unusable parts must not be re-used.

• Stabilizer, due to the use of pillow ball type connecting rod, the positioning of the ball
joint so that attachment of pillow ball head of the case is parallel to the stabilizer.
RSU

FAC0186D

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RSU - 15
 Rear suspension member

Rear suspension member PFP: 55501

Removal, installation JES002T7

removal

1. Remove the tire from the vehicle.

2. Remove the brake caliper, that you hang to a place that does not interfere with the brake caliper. " Caliper
A SSY Removal of, mounting "( BR-33 page ) See you confirm that you have read.

Caution : While it is removing the brake caliper, that you do not step on the brake pedal.

3. Remove the spare tire and the rack.

Four. Remove the rear exhaust tube. " Exhaust system "( EX-3 page ) See you confirm that you have read.

Five. Remove the stabilizer. " removal"( RSU-15 page ) See you confirm that you have read.

6. Remove the drive shaft. " Rear drive shaft "( RAX-8 page ) See you confirm that you have read.

7. Remove the final drive. " Rear final drive ASSY "( RFD-10 page ) See you confirm that you have read.

8. Remove the mounting portion of the mounting portion and the suspension members of the vehicle body of the parking brake cable. " parking

Brake control "( PB-4 page ) See you confirm that you have read.

9. Remove the rear lower link and coil spring. " Rear lower link and coil spring "( RSU-13 page ) The
See to it.

Ten. Set the jack to the rear suspension members.

11. Remove the rear suspension members after the side mounting nut.

12. Rear suspension member, suspension arm slowly lower the jack, front lower links and axle
A remove from the vehicle in one piece.

13. Remove the mounting bolt and nut, remove the front lower link from the rear suspension members.

14. Remove the mounting bolt and nut, remove the suspension arm from the rear suspension members.

Inspection after removal

Significant deformation to the rear suspension members, crack, inspect it for damage, if there is an abnormality, replace.

attachment
• "Rear suspension for each tightening torque, etc. ASSY " " Diagram"( RSU-4 page ) Refers to the, carried out in the reverse the removal procedure.

Caution : Look at the diagram, re unusable parts must not be re-used.

• It performs a final tightening of each part in the empty ground state, carry out the inspection of wheel alignment. " Inspection of wheel alignment "
(RSU-5 page ) See you confirm that you have read.

RSU - 16
 Service data

Service data PFP: 00030

Wheel Alignment JES002T8

Vehicle model Highway Star Except Highway Star

Camber - 0 ° Twenty '± Thirty ' - 0 ° 05 '± Thirty '

Toe-in In Six ~ 0 mm In 4mm ~ Out 2 mm

B

Ball joint JES002T9

Axial end play 0mm

Yo dynamic torque 0.5 ~ 3.4N - m { 0.06 ~ 0.34kg - m }

C
Measured value of the spring balance (cotter pin mounting holes) 7.9 ~ 54N { 0.81 ~ 5.5kg }

Week dynamic torque 0.5 ~ 3.4N - m { 0.06 ~ 0.34kg - m }

Tightening torque JES002U5

D
unit: N - m { kg - m }

Mount bracket-body 93 ~ 118 { 9.5 ~ Twelve }

Shock absorber - front lower link 55 ~ 70 { 5.7 ~ 7.1 }

Rear lower link-knuckle 80 ~ Hundred { 8.2 ~ Ten }

RSU
Suspension arm-knuckle 88.3 ~ 107 { 9.0 ~ 10.9 }

Front lower link-knuckle 105 ~ 130 { Eleven ~ 13 }

Radius rod-knuckle 110 ~ 135 { Twelve ~ 13 }

Radius rod - rear suspension member 80 ~ Hundred { 8.2 ~ Ten } F

Rear suspension member-body 82 ~ 101 { 8.4 ~ 101

The front lower link - rear suspension member 80 ~ Hundred { 8.2 ~ Ten }

Rear lower link - rear suspension member 80 ~ Hundred { 8.2 ~ Ten }

Suspension arm - rear suspension member 92 ~ 113 { 9.4 ~ Eleven } G

Stabilizer - connecting rod Hundred ~ 115 { 10.2 ~ 11.7 }

Clamp-rear suspension member 27 ~ Forty { 2.8 ~ 4.0 }

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RSU - 17
Service data

RSU - 18