Suspension System Front Suspension

Front Suspension
Specifications
Torque
Description Value
Nut - Front Shock Absorber to Steering Knuckle 110-130 Nm
Bolt - Front Lower Arm to Steering Knuckle 50-70 Nm
Nut - Connect Steering Gear Tie Rod to Steering Knuckle 35-45 Nm
Screw - Front Disc to Bearing 5-7 Nm
Bolt - Front Brake Caliper 85-105 Nm
Screw - Secure Front Wheel Speed Sensor to Steering 8-12 Nm
Knuckle
Bolt - Brake Hose Secures Front Brake Caliper 20-30 Nm
Screw - Front Brake Protector 4-8 Nm
Bolt (Rear) - Front Lower Arm to Sub Frame 110-130 Nm
Bolt (Front) - Front Lower Arm to Sub Frame 110-130 Nm
Nut - Front Lower Arm to Steering Knuckle 50-70 Nm

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Nut - Top of Front Shock Absorber 60-70 Nm
Nut - Anti Roll Bar Link to Anti Roll Bar 40-60 Nm
Nut - Front Shock Absorber Assembly to White Body 40-60 Nm
Bolt - Anti Roll Bar Bracket 30-40 Nm
Nut - Fit Anti Roll Bar Link to Front Shock Absorber 40-60 Nm
Bolt - Crash Bar to Sub Frame 64-77 Nm
Screw - Front Sub Frame to White Body 105-126 Nm
Nut - Crash Bar to Sub Frame 64-77 Nm
Bolt - Crash Bar Refit 36-43 Nm
Bolt - Adjust Front Sub Frame Strut Rod to Front Sub Frame 34-63 Nm

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Front Suspension Suspension System
Parameter
Model
Front Lower Arm The front suspension fixes the shock absorber and the "L"
shape lower arm out of the front sub frame, which prevents
the front suspension from tilting forward and backward

Anti Roll Bar Diameter 22 ± 0.3 mm

Front Spiral Spring Data
Total Turns 4.8
Effective Turns 3.8
Spring Wire Diameter 12 mm
Free Length to Minimum Length While Working 193.8-95 mm

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Suspension System Front Suspension

Description and Operation

System Component Layout
Front Suspension Component Layout

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1. Front Suspension Shock Absorber Assembly 6. Anti Roll Bar Bushing Clamp
2. Anti Roll Bar Link 7. Front Lower Arm Assembly
3. Front Sub Frame Assembly 8. Crash Bar Assembly
4. Anti Roll Bar 9. Sub Frame Rear Mounting Support Plate
5. Front Hub Assembly 10. Front Sub Frame Strut Bar

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Front Suspension
Front Suspension Exploded View
1. Front Shock Absorber Pillar
2. Anti Roll Bar Link
3. Anti Roll Bar Holder Bracket
4. Anti Roll Bar
5. Anti Roll Bar Bushing
6. Front Lower Arm Front Bushing
7. Front Lower Arm Rear Bushing
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Suspension System
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8. Front Hub
9. Front Hub Bearing
10. Front Hub Elastic Backup Ring
11. Front Drive Shaft Nut
12. Front Shock Absorber Spiral Spring
13. Front Lower Arm
14. Front Hub Flange
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Suspension System
Front Shock Absorber Exploded View
1. Front Shock Absorber Pillar
2. Front Shock Absorber Insulation Cap
3. Front Shock Absorber Upper Support Seat Assembly
4. Front Shock Absorber Lower Spring Pad
5. Front Shock Absorber Pillar Dust Cover
V 2.0
Front Suspension
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6. Front Suspension Spiral Spring
7. Front Shock Absorber Pillar Assist Spring
8. Nut - Front Shock Absorber Top Support
9. Nut - Front Shock Absorber Pillar to Body
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Front Suspension
Description
The front suspension consists of:
• 2 Shock Absorbers
• 2 Front Lower Arms
• Anti Roll Bar
• 2 Anti Roll Bar Links
• Front Sub Frame
• Front Hub, Bearing and Drive Flange
The anti roll bar and the 1:1 shock absorber gear ratio make
the design of the front suspension have the characteristic
of pitching. Because of the adoption of lateral force
compensation spring, the arrangement and design of the shock
absorber minimizes the wheel camber loss caused by the
lateral force applied to the shock absorber itself, improving
the responsiveness of controlling and steering.
5.2.2.1 Front Sub Frame Assembly
The front sub frame with the characteristics of light weight
and high structure strength is produced through stamping and
welding. The geometric dimensions of all the key positions
are machined after the front sub frame is produced, which
can ensure the components of the front suspension and the
steering system have accurate positions. The front sub frame
strut rod equipped between the front sub frame front fulcrum
and the body can improve the rigidity of the front sub frame.
The arrangement of the fulcrum prevents the front sub frame
from moving under lateral force, and the movement could lead
to an unnecessary steering effect.
5.2.2.2 Front Shock Absorber Assembly
The front shock absorber adopts the inflated twin-tube
structure, and can be inflated and refilled. This kind of
twin-tube structure allows the shock absorber piston to move
in the inner tube, and there is an oil discharge hole which is
located between the inner tube and the outer tube on the
inner tube, this structure minimizes possibility of the gas cavity
phenomenon, and avoid affecting the piston's movement due
to outer tube's damage. The lower end of the front shock
absorber is connected to the front hub, and secured with
the lock bolt. The bottom of the front shock absorber is
fixed on the front hub to ensure a correct guide for front
shock absorber. The front shock absorber column is seated
in the bush rubber in which the steel plate inlaid, and the
V 2.0
Suspension System
bush rubber is integrated with the upper mounting carrier
group. The front shock absorber column is tightened with
the nut and washer. There is an outer hexagonal end face on
the end of the front shock absorber column, which can be
used to limit the column and prevent it from rotating when
tightening the nuts of the front shock absorber column. The
front shock absorber column is sealed in the shock absorber
with low-friction material. The spring seat with a certain angle
is integrated with the shock absorber body, and also can be
used as the connection fitted point of the anti roll bar link.
5.2.2.3 Front Lower Arm Assembly
The front lower arm connects the front hub and the front sub
frame. There is an outer ball joint with a straight pin on the
front lower arm. The pin can be fitted on the opening of the
front hub bottom, and clamped on the proper position with a
bolt and a lock nut.
5.2.2.4 Anti Roll Bar and Link
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The anti roll bar made of solid spring steel operates through
the anti roll bar link, and the anti roll bar link is connected
to the spring seat of the front shock absorber column. PTFE
bushing is secured with the bolt and the anti roll bar holder
bracket. The PTFE bushing has low friction, needs no extra
lubrication and makes the anti roll bar rotate freely in static
state, this makes the anti roll bar respond to the input of the
rollover quickly, and the bushing with higher rigidity is allowed
to be used when no compression and twist operation for the
general bushing is found. The ripple washers seated on the anti
roll bar, the outboard of each bushing can prevent the anti roll
bar from moving towards the side direction. The tail end of the
anti roll bar is connected to the spring seat of the front shock
absorber through the anti roll bar link. The arrangement allows
the anti roll bar to operate at a 1:1 rate with the wheels stroke
in order to provide the maximum lateral stable efficiency. The
ball joint is fitted on the end of each anti roll bar link, and
the ball joint can improve the speed of response and efficiency.
The upper ball joint fixed with the lock nut locates on the axial
lead of the anti roll bar link, and connected to the front shock
absorber spring seat directly. The link must be connected to
the rear ball joint of the anti roll bar, and the lock surface of the
lock nut should face the inside of the vehicle. The ball joints
on the anti roll bar link cannot be repaired, and if any of them
needs to be replaced, replace the anti roll bar link assembly
with a new one.
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Suspension System Front Suspension

Service Procedures
Front Hub Assembly
Removal
1. Raise the vehicle on a lift.

Wheel
2. Remove the front wheel.
3. Loosen the brake hose from brake caliper.
4. Loosen theABS sensor wire from the bracket.
5. Remove the 2 bolts securing the brake caliper to the
front hub.

10. Remove the screw securing theABS speed sensor,

loosen the sensor and put it aside.

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Caution: DO NOT hang the brake caliper on brake hose.
6. Remove the countersunk head screw securing the
brake disc to the drive flange.
11. Remove the nuts and bolts securing the front lower
arm outer ball joint to the front hub.

7. Remove the front disc.

8. Remove the nuts securing the steering rod to the
12. Fit the front lower arm ball joint protector.
steering knuckle.
9. Loosen the steering rod ball joint from the steering Notice: Be sure to fit the ball joint protector to avoid damaging the
knuckle with the tool T38008. ball joint.
13. Remove the bolts securing the front shock absorber
assembly to the front hub.
14. Loosen the bolts connecting the wheel steering knuckle
to the pillar and spring assembly.
15. Remove the front hub.

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Front Suspension Suspension System
Caution: DO NOT place the rear hub bearings near the Front Hub Bearing
magnetic fields or chips, as it may damage the bearing. Removal
Caution: DO NOT remove the protective cover from hub 1. Remove the front hub assembly.
bearing unless the hub is about to be fitted. Front Hub Assembly
Refit 2. Remove the 3 bolts securing the front disc protector.
1. Clean the connection of the front hub and the front 3. Position the front hub.
shock absorber.
2. Clean the drive shaft assembly and the flange spline.
3. Clean the connection from the front hub to the front
lower arm ball joint.
4. Fit the front hub to the front shock absorber assembly.
5. Connect the front hub to the front lower arm assembly.
Notice: DO NOT touch the front lower arm ball joint to prevent
damaging it.
6. Fit the bolts securing the front shock absorber assembly
to the front hub and tighten them to 110-130 Nm.

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7. Make sure that the front lower arm outer ball joint is
fully engaged with the front hub, and the bolt is fitted in
4. Fit the toolTCH00007 to the front drive flange, then
the groove of the front lower arm outer ball joint.
press the drive flange from the front hub bearing and
8. Fit the nuts and bolts securing the front lower arm
separate it.
assembly to the front hub, and tighten them to 50-70
5. Remove the front disc protector.
Nm.
6. Remove the bearing inner race from the drive flange
9. Clean the connection of the steering rod and the
with the tool TCH00007.
steering knuckle.
10. Connect the steering rod to the steering knuckle, fit
the lock nut and tighten it to 35-45 Nm.
11. Fit the front disc to the front drive flange, fit the
countersunk head screw and tighten it to 5-7 Nm.
12. Loosen the front brake caliper assembly and position it
to the front disc. Fit the bolts securing the front brake
caliper to the front hub, and tighten them to 85-105
Nm.
13. Secure the front brake hose to the front shock absorber
jumper bracket with a tube clamp.
14. Secure the front wheelABS sensor wire harness to the
steering knuckle, and tighten the screw to 8-12 Nm.
7. Remove the front hub bearing backup ring from the
15. Tighten the 4 bolts securing the brake hose to the
front hub.
brake caliper to 20-30 Nm.
8. Fit the toolTCH00004 to the front hub bearing, and
16. Fit the wheels.
simultaneously press the bearing from the front hub
Wheel with the tool TCH00003Press the bearing from the
17. Lower the vehicle. front hub.
18. Check the wheel alignment parameter.
Four-wheel Alignment

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Suspension System Front Suspension

Front Lower Arm Assembly

Removal
1. Raise the vehicle on a lift.
2. Remove the front wheel.
Wheel
3. Loosen the lower arm outer ball joint from the front
hub.
4. Fit the front lower arm outer ball joint protector.
Notice: Be sure to fit the ball joint protector to avoid damaging the
ball joint.
5. Remove the nuts and bolts of the rear lower arm
Refit bushing and sub frame.

1. Clean the connection of the front hub and bearing.

2. Support the front hub on the tool TCH00005, and
press in a new bearing with the tool TCH00002.

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6. Remove the bolt from the front lower arm bushing to
the sub frame welding nuts.

3. Fit the front hub bearing backup ring to the front hub.
4. Fit the front disc protector, and tighten the bolt to
4-8 Nm.
5. Support the front hub bearing on the tool TCH00005,
and press the drive flange into the front hub bearing
with the tool TCH00006.

7. Remove the front lower arm assembly.

Refit
1. Connect the control arm rear bushing and the
corresponding hole position of the sub frame with the
bolts, tighten the nuts and bolts of the lower arm rear
bushing and the sub frame to 110-130 Nm.
2. Place the lower arm on the corresponding hole position
of the sub frame, tighten the bolts of the welding nuts
from the lower arm front bushing to the sub frame to
110-130 Nm.
3. Remove the front lower arm ball joint protector, and
check the ball joint protector for damage.
4. Connect the front lower arm outer ball joint to the
front hub. Fit the nuts and bolts, and tighten the front

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Front Suspension Suspension System
hub to 50-70 Nm. Front Lower Arm Rear Bushing
5. Fit the wheels. Removal

Wheel 1. Remove the front lower arm

6. Lower the vehicle. Front Lower Arm Assembly

7. Check the wheel alignment parameter. 2. Remove the front lower arm bushing and the bracket
assembly using the toolsTCH00008 and TCH00009.
Four-wheel Alignment

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Refit
1. Clean the connection of the front lower arm and the
front lower arm bushing.
2. Position the front lower arm bushing on the front lower
arm, make sure that the bushing aligns the mark on the
front lower arm.
3. Press the front lower arm bushing onto the front lower
arm using the toolsTCH00009 and TCH00010, until
it aligns the mark on the front lower arm.

4. Fit the front lower arm assembly.

Front Lower Arm Assembly

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Suspension System Front Suspension

Front Lower Arm Front Bushing Front Shock Absorber Assembly

Removal Removal
1. Remove the front lower arm 1. Raise the vehicle on a lift.
Front Lower Arm Assembly 2. Remove the front wheel.
2. Remove the front lower arm bushing and the bracket Wheel
assembly using the toolsTCH00013 and TCH00014. 3. Loosen the engine bay shock absorber column upper
cover and the nuts.

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Refit
1. Clean the connection of the front lower arm and the 4. Loosen theABS sensor wire harness and the brake
front lower arm bushing. hose from the front shock absorber. Loosen the wire
harness and brake hose from the attaching clamp.
2. Position the front lower arm bushing on the front lower
arm, make sure that the bushing aligns the mark on the 5. Remove the nuts from the anti roll bar link to the strut
front lower arm. assembly, and disconnect the anti roll bar link.

3. Press the front lower arm bushing onto the front lower
arm using the toolsTCH00011 and TCH00012, until
it aligns the mark on the front lower arm.

6. Remove the nuts and bolts from the steering knuckle

4. Fit the front lower arm. to the shock absorber column assembly to disconnect
the steering knuckle.
Front Lower Arm Assembly

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Front Suspension
7. Remove the shock absorber column assembly.
8. Secure the spring compressor toolsT32016
andT32017 to the front shock absorber spring.
9. Make sure that the spring compressor claw is positioned
accurately, and compress the spring.
10. Pry the front shock absorber insulation cap, clamp
the top of the front shock absorber column using the
toolsT32016 andT32017 and remove the nuts on the
column top and dispose of them.
11. Remove the front shock absorber rebound washer
and the front shock absorber upper mounting holder
assembly.
12. Remove the spring insulator.
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Suspension System
13. Remove the front shock absorber spiral spring.
14. Remove the front shock absorber compression travel
block washer, the front shock absorber compression
travel block and the front shock absorber dust cover.
15. Release the spiral spring pressure, loosen the claw from
the spring compressor and remove the spiral spring.
Refit
1. Check the front shock absorber column, the upper and
lower insulators of the spring, the bearing of the front
shock absorber for crack and damage.
2. Check the front shock absorber dust cover and the
front shock absorber compression travel block for signs
of deterioration or damage.
3. Clean the front shock absorber column and the front
shock absorber compression travel block washer.
4. Fit the front shock absorber compression travel block,
the front shock absorber compression travel block
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washer and the front shock absorber column dust
cover to the front shock absorber assembly.
5. Make sure that the front shock absorber compression
travel block and the front shock absorber compression
travel block washer are positioned on the front shock
absorber column dust cover correctly.
6. Fit the front shock absorber spiral spring to the front
shock absorber column.
7. Position the spring compressor on the front shock
absorber, compress the spring with the toolsT32016
and T32017.
8. Make sure that the relative mounting position is correct,
and fit the front shock absorber upper mounting holder
and the front shock absorber spring insulator to the
front shock absorber shaft.
9. Fit the front shock absorber rebound washer and the
new nut.
10. Clamp the front shock absorber column using the inner
hexagon wrench, and tighten the nut to 60-70 Nm.
11. Release the elastic force of the spring, loosen the spring
compressor claw and remove the spring compressor.
12. Connect the front shock absorber column assembly
to the steering knuckle, and tighten the nuts and bolts
from the steering knuckle to the front shock absorber
column assembly to 110-130 Nm.
13. Connect the anti roll bar link to the shock absorber
column assembly, tighten the nuts from the anti roll
bar link to the shock absorber column assembly to
40-60 Nm.
14. Fit the front brake hose and the front wheelABS
sensor wire harness to the front shock absorber
column bracket.
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Suspension System Front Suspension

15. Fit the wheels. Anti Roll Bar

Wheel
Removal
1. Raise the vehicle on a lift.
16. Lower the vehicle.
2. Remove the front wheel.
17. Fit the engine bay shock absorber column upper cover
and the nuts to 40-60 Nm. Wheel
18. Check the wheel alignment parameter. Caution: The nuts and bolts must be tightened when the
weight of vehicle is applied to the suspension.
Four-wheel Alignment
3. Remove the nuts securing the anti roll bar link to the
anti roll bar.
4. Disconnect the anti roll bar link.
5. Remove the front sub frame assembly.
Front Sub Frame Assembly Removal

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6. Remove the 4 bolts securing the anti roll bar bushing
bracket to the front sub frame assembly.

Refit
1. Secure the anti roll bar bushing bracket to the front sub
frame, and tighten the bolts to 30-40 Nm.
2. Fit the front sub frame assembly.
Front Sub Frame Assembly Refit
3. Tighten the nuts from the anti roll bar to the anti roll
bar link to 40-60 Nm.
4. Fit the wheels.
Caution: The nuts and bolts must be tightened when the
weight of vehicle is applied to the suspension.

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Front Suspension Suspension System
Wheel Anti Roll Bar Bushing
5. Lower the vehicle. Removal
6. Check the wheel alignment parameter. 1. Raise the vehicle on a lift.
2. Remove the front wheel.
Four-wheel Alignment
Wheel
3. Remove the front sub frame assembly.
Front Sub Frame Assembly Removal
4. Remove the anti roll bar.
Anti Roll Bar
5. Remove the anti roll bar holder bracket and the bushing.

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Refit
1. Fit the bushing to the anti roll bar and position it on
the bracket.
Caution: Anti roll bar bushes have a special coating and
must not be lubricated.
2. Fit the bushing holder bracket.
3. Fit the bolts securing the bushing bracket, and tighten
each of them in order to 30-40 Nm.
4. Fit the front sub frame assembly.
Front Sub Frame Assembly Refit
5. Fit the wheels.
Wheel

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Suspension System Front Suspension

Anti Roll Bar Link Front Sub Frame Assembly

Removal Removal
1. Raise the vehicle on a lift. 1. Raise the vehicle on a lift.
2. Remove the front wheel. 2. Remove the front wheel.
Wheel Wheel
3. Remove the nuts securing the anti roll bar link to the 3. Remove the exhaust pipe.
anti roll bar. Exhaust Pipe
4. Remove the engine rear lower tie bar.
5. Disconnect the steering rod from the steering knuckle
assembly.
6. Disconnect the ball joint from the steering knuckle
assembly.
7. Disconnect the anti roll bar from the front shock
absorber assembly.
Notice: When removing the front service bolt, there must be two

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technicians holding the front crossmember assembly and supporting
the assembly with the jack properly. Improperly supported front
crossmember may cause personal injury.

4. Disconnect the anti roll bar link. 8. Remove the 4 bolts securing the crash bar to the white
5. Turn the front shock absorber column to touch the set body.
nuts on the anti roll bar link. 9. Remove the 4 mounting bolts securing the front sub
6. Remove the nuts securing the anti roll bar link to the frame support plate.
front shock absorber.
Caution: To prevent damage to components, use two
wrenches simultaneously when loosening or tightening
the tube unions.
7. Remove the anti roll bar link from the front shock
absorber.
Refit
1. Fit the anti roll bar link to the front shock absorber,
and tighten the nuts to 40-60 Nm.
Caution: To prevent damage to components, use two
wrenches simultaneously when loosening or tightening
the tube unions. 10. Remove the 4 screws securing the front sub frame to
2. Connect the anti roll bar link to the anti roll bar, and the white body.
tighten the nuts to 40-60 Nm. 11. Remove the front sub frame assembly from the vehicle.
3. Fit the wheels. 12. Remove the 4 bolts securing the crash bar to the front
sub frame.
Wheel
Refit
4. Lower the vehicle.
1. Tighten the 4 bolts securing the crash bar to the front
5. Check the wheel alignment parameter.
sub frame to 64-77 Nm.
Four-wheel Alignment
2. Adjust the sub frame to a proper position to insert the
mounting shaft of the body to the two mounting points
behind the sub frame.
3. Tighten the 4 bolts securing the front sub frame to the
white body to 105-126 Nm.

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Front Suspension Suspension System
4. Tighten the 4 bolts securing the front sub frame bracing
plate to 64-77 Nm.
5. Tighten the 4 bolts securing the crash bar to the white
body to 36-43 Nm.
6. Adjust the front sub frame support to the front sub
frame, and tighten the bolt to 34-63 Nm.
7. Connect the anti roll bar to the front shock absorber
column assembly.
8. Connect the ball joint to the steering knuckle assembly.
9. Connect the steering rod to the steering knuckle
assembly.
10. Fit the exhaust pipe to the vehicle.

Exhaust Pipe
11. Fit the wheels.
Wheel
12. Lower the vehicle.

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13. Check the wheel alignment parameter.
Four-wheel Alignment

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Suspension System Front Suspension

Special Tools Tool Description Picture

Tool Description Picture Number
Number

Front Hub
Ball Joint TCH00002 Bearing
T38008 Removal Replacer
Fixture

Front Hub
Front Hub TCH00006 Drive Flange
TCH00007 Drive Flange Replacer
Remover

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Front Hub
Bearing Front Arm (big)
TCH00004 TCH00008
Removal Bush Remover
Support

Front Arm (big)

Front Hub
TCH00009 Bush Replacer
TCH00003 Bearing
Support
Remover

Front Hub
Bearing and Front Arm (big)
TCH00010
TCH00005 Drive Flange Bush Replacer
Mounting
Support

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Front Suspension Suspension System
Tool Description Picture Tool Description Picture
Number Number

Front Arm Front

TCH00013 (small) Bush Suspension
Remover T32016
Spring
Compressor

Front Arm
(small) Bush Front
TCH00014
Removal Suspension
Support T32017 Spring
Compressor
Adaptor

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Front Arm
TCH00011 (small) Bush
Replacer

Front Arm
(small) Bush
TCH00012
Mounting
Support

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