General: 2001 Suspension Front - Rio

2001 Kia Rio
2001 Suspension Front - Rio
2001 Suspension
Front - Rio
GENERAL
SPECIAL SERVICE TOOLS
Fig. 1: Front & Rear Suspension Service Tools
TROUBLESHOOTING GUIDE
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2001 Kia Rio
Fig. 2: Front & Rear Suspension System Troubleshooting Guide (1 Of 3)
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October-30-07 4:05:13 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
2001 Kia Rio
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2001 Kia Rio
DESCRIPTION & OPERATION

The front suspension system on Rio is a typical MacPherson strut layout with single pivot forged control arms.
The front suspension consists of the following :
z A transverse front tension rod that limits sway and doubles as a trailing arm on each side to maintain
control arm alignment.
z The control arms include integral ball joints which allow steering and ride travel of the wheels. The
wheels are mounted on steering knuckles clamped to the control arm ball joints and bolted to the strut
lower ends.
z The upper ends of the struts are seated in towers in the engine compartment. Caster and camber are not
adjustable.
z Rubber bushings at the control arm and tension rod mounting points cushion road shocks.
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2001 Kia Rio
Fig. 5: Illustrating Front Suspension Components
INSPECTION & ADJUSTMENTS
NOTE: For alignment specifications and adjustments, see SPECIFICATIONS &

PROCEDURES .
COIL SPRING
If loading is normal and vehicle attitude is not, check for spring damage, spring sag, or non-standard
replacement springs.
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2001 Kia Rio
Fig. 6: Inspecting Coil Springs
STRUTS
Bounce test the vehicle at each front corner and at the rear bumper to check the strut function. Damping action
should be positive and uniform all around. Inspect the struts for evidence of oil leakage. A thin film is normal.
Check the rear strut upper bushing by shake-testing with the vehicle raised just enough to unload the struts
(wheels still on the ground). Any looseness is indicative of worn or deteriorated bushings, which must be
replaced.
LOWER ARM
Check the following points, repair or replace if necessary.
1. Loose installation bolts and nuts.

2. Deformation or cracks in the lower arm
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2001 Kia Rio
Fig. 7: Illustrating Lower Arm
TENSION ROD
Check the following points or replace if necessary.
1. Looseness of the installation bolts and nuts.

2. Worn or deteriorated bushing.
REMOVAL, DISASSEMBLY, INSPECTION, REASSEMBLY & INSTALLATION

FRONT MACPHERSON STRUT AND SPRING
Raise the front of the vehicle and support it with safety stands.
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2001 Kia Rio
Fig. 8: Illustrating Front Strut Assembly
REMOVAL
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2001 Kia Rio
Raise the front of the vehicle and support it with safety stands.
1. Remove the clip of the strut side.

2. Remove the flexible hose and ABS sensor cable from the strut bracket.
Fig. 9: Removing The Flexible Hose & ABS Sensor Cable
3. Remove the stabilizer control link from the bracket mounted to the strut.
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2001 Kia Rio
Fig. 10: Removing The Stabilizer Control Link From The Bracket Mounted To The Strut
4. Detach the knuckle from the strut.
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2001 Kia Rio
Fig. 11: Detaching The Knuckle From The Strut
5. Remove the attaching nut.

6. Remove the strut from suspension tower.
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2001 Kia Rio
Fig. 12: Removing Strut From Tower
DISASSEMBLY
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2001 Kia Rio
Fig. 13: Illustrating Front Strut Assembly Components
1. Secure the mounting block in a vise.
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2001 Kia Rio
CAUTION: Use protective plates in the jaws of the vise
2. Loosen the piston rod nut a few turns. Do not remove nut.
CAUTION: Do not remove the nut.
Fig. 14: Loosening The Piston Rod Nut
3. Use the SST or equivalent, and compress the spring to unload the strut.
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2001 Kia Rio
Fig. 15: Compressing The Coil Spring
4. Remove the strut nut and lock washer.

5. Remove the strut mounting block and plate.
6. Remove the bearing from the strut rod.
7. Remove the spring seat, seat rubber and spring.
8. Slide the bump stopper off the strut.
CAUTION: If replacing a spring, release the spring compressor progressively to

prevent spring arching. Open the compressor jaws wide enough to
grip the new spring in the same position, and tighten the compressor
screws progressively, compressing the spring until the strut can be
assembled without interference.
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2001 Kia Rio
Fig. 16: Removing Coil Spring
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2001 Kia Rio
Fig. 17: Releasing Spring Compressor Progressively
9. Before assembly, inspect the struts.
INSPECTION
Check the following points, repair or replace if necessary.
1. Oil leakage or abnormal noise from the MacPherson strut.

2. Deterioration or damage to the mounting block.
3. Damaged or loose bearing. Wear or damage to bump stopper.
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2001 Kia Rio
Fig. 18: Inspecting Strut Assembly Components
REASSEMBLY
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2001 Kia Rio
1. Slide the bump stopper onto the strut rod and over the body.
2. Install the compressed spring, seat rubber, and upper spring seat, positioning the spring ends against the
step in the seats.
3. Install the bearing on the strut rod.
4. Install the strut mounting block with the white alignment spot on the same side of the strut as the steering
knuckle mounting bracket.
5. Install the plate.
Fig. 19: Compressing Coil Spring Assembly
6. Temporarily tighten strut rod nut by hand.

7. Release and remove the spring compressor.
8. Secure the strut rod in the mounting block with the lock washer and strut rod nut.
Tightening torque:
41-50 lb.ft (55-68 N.m, 5.6-6.9 kg.m)
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2001 Kia Rio
Fig. 20: Tightening Strut Rod Nut
INSTALLATION
1. Position the strut, with adjusting plate in place into the strut tower with the raised rubber mounting facing
in board.
2. Install the strut mounting block nuts.
Tightening torque:
34-46 lb.ft (46-63 N.m, 4.7-6.4 kg.m)
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2001 Kia Rio
Fig. 21: Installing Strut To Tower
3. Install the steering knuckle in the strut lower bracket and install the two strut lower bracket nuts with
attaching nuts.
Tightening torque:
76-90.4 lb.ft (103-123 N.m, 10.5-12.5 kg.m)
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2001 Kia Rio
Fig. 22: Installing Strut Lower Mounting Bolts & Nuts
4. Install the stabilizer control link to the bracket mounted to the strut.
Tightening torque:
32-45 lb.ft (43-60.8 N.m, 4.4-6.2 kg.m).
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2001 Kia Rio
Fig. 23: Installing The Stabilizer Control Link
5. Position the brake line and ABS sensor cable in the cutout on the strut lower bracket and secure it with
the brake line clip.
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2001 Kia Rio
Fig. 24: Installing Brake Line & ABS Sensor Cable
LOWER ARM
COMPONENT
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2001 Kia Rio
Fig. 25: Illustrating Lower Arm & Tension Rod Component
REMOVAL
1. Jack up the front of the vehicle and support it with safety stands.
2. Remove the wheel and tire.
3. Remove the tension rod attaching bolt at the frame bracket.
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2001 Kia Rio
Fig. 26: Removing The Tension Rod Attaching Bolt
4. Remove the tension rod bushing cotter pin and attaching nut from rear of the lower arm, and remove the
washer and bushing.
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2001 Kia Rio
Fig. 27: Removing Tension Rod
5. Pull the tension rod out of the lower arm and remove the front bushing and washer.
6. Lower the lower arm, prying the ball joint stud out of the steering knuckle, after loosening bolt and nut.
7. Remove the lower arm after loosening the lower arm attaching bolt from the frame bracket.
INSPECTION
Check the following points, replace if necessary.
1. Deformation or cracks in lower arm.

2. Deformation or wear of bushing.
3. Rotation torque of ball-joint.
4. Connect the SST to the ball stud, and measure the torque with a pull scale.
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2001 Kia Rio
Rotation torque:
7.2-25.2 lb.ft (1.0-3.5 N.m, 10-35 kg.cm)
Pull scale reading :
2.2-7.7 lb (10-35 N, 1-3.5 kg)
Fig. 28: Measuring Ball Joint Rotation Torque
INSTALLATION
1. Raise the inner end of the lower arm into the pivot bracket on the frame, and loosely tighten the arm
frame bracket pivot to hold it in place.
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2001 Kia Rio
2. Position the lower arm ball joint stud in the clamp bore of the steering knuckle and install the ball joint
clamp bolt and nut.
Tightening torque:
40-50 lb.ft (54-68 N.m, 5.5-6.9 kgm)
3. Tighten the lower arm frame bracket pivot bolt.
Tightening torque:
40-50 lb.ft (54-68 N.m, 5.5-6.9 kgm).
4. Insert the tension rod bolt into to the lower arm, tighten washer and bushing, and install cotter pin.
5. Install bushing and rubber on the tension rod.
Tightening torque:
87-108 lb.ft (118-147 N.m, 12-15 kg.m)
FRONT STABILIZER BAR
COMPONENT
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2001 Kia Rio
Fig. 29: Identifying Front Stabilizer Bar Components
REMOVAL
1. Support engine with SST (OK201 170 AAOA).

2. Raise and support the vehicle with safety stand.
3. Remove wheel and tire.
4. Remove the stabilizer from the stabilizer control link.
5. Remove the control link from the control link bracket on the strut.
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2001 Kia Rio
Fig. 30: Removing The Control Link
6. Remove the stabilizer bar mounting bracket attaching bolt and mounting bracket.
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2001 Kia Rio
Fig. 31: Removing The Stabilizer Bar Mounting Bracket
7. Remove the engine-mounting member bolts and nuts from the front side of the engine-mounting member.
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2001 Kia Rio
Fig. 32: Removing The Engine-Mounting Member
8. Lower the engine-mounting member enough to pull the stabilizer out from the engine-mounting member.
9. Remove the stabilizer bar.
INSPECTION
Check the following points and replace if necessary.
1. Worn or deteriorated rubber bushing.

2. Bent, cracked, or damaged stabilizer.
INSTALLATION
1. Align the stabilizer bushing with the installation position line painted on the stabilizer bar. Locate the
bushing adjacent to the position line on stabilizer bar.
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2001 Kia Rio
Fig. 33: Aligning The Stabilizer Bushing
2. Position stabilizer forward of the engine-mounting member.

3. Raise the engine-mounting member into place and tighten the engine-mounting member bolts and nuts on
the front side of the engine-mounting member.
Tightening torque:
Bolt: 47-66 lb.ft (65-9 N.m, 6.5-9.1 kg.m)
Nut: 28-38 lb.ft (39-52 N.m, 3.9-5.3 kg.m)
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2001 Kia Rio
Fig. 34: Installing Engine-Mounting Member
4. Install the stabilizer bar mounting bracket attaching bolt and mounting bracket and tighten the attaching
bolt.
Tightening torque:
26-42 lb.ft (36-56 N.m, 3.7-5.8 kg.m)
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2001 Kia Rio
Fig. 35: Installing The Stabilizer Bar Mounting Bracket
5. Install the stabilizer control link onto control link bracket on the strut.
Tightening torque:
32-45 lb.ft (43-60.8 N.m, 4.4-6.2 kg.m)
6. Install the stabilizer bar on the stabilizer control link.
Tightening torque:
32-45 lb.ft (43-60.8 N.m, 4.4-6.2 kg.m)
NOTE: Tighten the two stabilizer control link nuts to specified torque before
lowering vehicle (unload condition).
7. Install the wheel and tire.

8. Lower the vehicle.
9. Remove the SST (201 170 AAOA) from engine.
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2004 Hummer H2
2003-04 SUSPENSION General Diagnosis - H2
2003-04 SUSPENSION
General Diagnosis - H2
TRIM HEIGHT SPECIFICATIONS
Fig. 1: Trim Height Specifications

Courtesy of GENERAL MOTORS CORP.
DIAGNOSTIC INFORMATION
DIAGNOSTIC STARTING POINT - SUSPENSION GENERAL DIAGNOSIS
Begin the system diagnosis by reviewing the system Description & Operation. See REAR SUSPENSION -
H2 . Reviewing the Description and Operation information will help you determine the correct symptom
diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information, and the
vehicle RPO, will also help you determine if the condition described by the customer is normal operation. See
SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS in order to identify the correct procedure for
diagnosing the system and where the procedure is located.
SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS
The following steps must be completed before using the symptom tables.
1. Determine whether the vehicle is equipped with an electrically assisted or active suspension system.
Perform electrical diagnosis prior to beginning mechanical diagnosis.
2. Review the system description and operation in order to familiarize yourself with the system functions.
Refer to the appropriate description and operation:
z General Description in Front Suspension.
z General Description in Rear Suspension.
Visual/Physical Inspection
z Inspect for aftermarket devices which could affect the operation of any of the suspension subsystems.
z Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
z Inspect for proper tire size and inflation pressure.
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2004 Hummer H2
Symptom List
z BALL JOINT INSPECTION (LOWER BALL JOINT)

z BALL JOINT INSPECTION (UPPER BALL JOINT)
z BODY LEANS OR SWAYS IN CORNERS
z MEMORY STEER
z NOISE DIAGNOSIS - FRONT SUSPENSION
z NOISE DIAGNOSIS - REAR SUSPENSION
z POOR DIRECTIONAL STABILITY
z RIDE DIAGNOSIS
z STRUTS OR SHOCK ABSORBERS ON-VEHICLE TESTING
z SUSPENSION BOTTOMS
z TRIM HEIGHT INSPECTION PROCEDURE
z VEHICLE LEADS/PULLS
z WHEEL BEARING DIAGNOSIS
BALL JOINT INSPECTION (LOWER BALL JOINT)
1. Raise and support the vehicle.

2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is
present. If vertical free play is experienced proceed with the following instructions.
4. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball
joint.
5. Install and position the dial indicator from J-8001 against the end of the ball joint. See SPECIAL
TOOLS .
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2004 Hummer H2
Fig. 2: Positioning Dial Indicator To Lower Ball Joint

6.
NOTE: Do not pry between the lower arm and the wheel drive shaft boot or in
such a manner that the ball joint seal is contacted. Damage to the wheel
drive shaft boot will result (4WD).
Gently lift or pry the suspension upward then let it settle.

7. The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is out of specification,
replace the ball joint.
BALL JOINT INSPECTION (UPPER BALL JOINT)

2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is
present. If vertical free play is experienced proceed with the following instructions. Remove the wheel
and tire.
4. Support the lower control arm with a floor stand or jack, as far outboard as possible.
5. If a seal is cut or torn, replace the ball joint.
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2004 Hummer H2
6. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball
joint.
7. Check the wheel bearing for looseness in the wheel bearing is present, refer to WHEEL BEARING
DIAGNOSIS .
8. Check the upper ball joint for vertical looseness.
9. Remove the lower shock absorber mounting bolt. This will ensure that the suspension is unloaded.
10. Install and position the dial indicator from J-8001 against the rim of the upper ball joint. See SPECIAL
TOOLS .
Fig. 3: Positioning Dial Indicator To Upper Ball Joint

11. Apply downward force to the upper control arm and zero the indicator pointer/pad against the rim of the
upper ball joint.
12. Release the arm and check the dial indicator. The dial indicator reading should be no more than 2 mm
(0.079 in). If the reading is too high, replace the upper control arm.
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2004 Hummer H2
BODY LEANS OR SWAYS IN CORNERS
1. Did you review the General Description and perform the necessary inspections? If yes, go to next step. If
no, go to SYMPTOMS - SUSPENSION GENERAL DIAGNOSIS .
2. Verify the vehicle leans or sways in corners. Does the vehicle operate normally? If yes, then system is
okay. If no, go to next step.
3. Inspect the rear coil springs and torsion bars for wear or damage. Are the components worn or damaged?
Are the components worn or damaged? If yes, go to step 5 . If no, go to next step.
4. Inspect the stabilizer shaft link for wear or damage. Is the stabilizer shaft link worn or damaged? If yes,
go to step 6 . If no, go to step 2 .
5. Replace the springs. Refer to the appropriate procedure:
z Coil Spring Replacement in Rear Suspension.
z Torsion Bar Replacement in Front Suspension.
After repair is complete, go to step 7 .

6. Replace the stabilizer shaft link. Refer to GENERAL DIAGNOSIS - H2 . After repair is complete, go to
next step.
7. Operate the vehicle in order to verify the repair. Did you correct the condition? If yes, then system is
okay. If no, go to step 3 .
MEMORY STEER
DEFINITION: The steering wheel does not return to center after completing a turn.
2. Verify that memory steer is present. Does the system operate normally? If yes, system is okay. If no, go
to next step.
3. Check the tire inflation and adjust to specifications. Did you adjust the tire pressure? If yes, go to step 13 .
If no, go to next step.
4. Raise and support the vehicle. Lubricate the tie rod ends and the ball joints if applicable. Inspect the
suspension system for worn or damaged components. Repair as necessary. Did you find and correct the
condition? If yes, go to step 13 . If no, go to next step.
5. Rotate the steering wheel ONE revolution in both directions. Rotate the steering wheel back to the
original position. Was the steering wheel abnormally difficult to rotate in either direction? If yes, go to
next step. If no, go to step 9 .
6.
NOTE: Do NOT rotate the steering wheel more than one complete revolution.
Remove the steering column pinch bolt in order to disengage the column from the steering system. Note
the position of the steering wheel and rotate the steering wheel ONE revolution in both directions. Rotate
the steering wheel back to the original position. Was the steering wheel abnormally difficult to rotate in
either direction? If yes, go to step 12 . If no, go to next step.
7. Remove the front tire and wheel assemblies. Disconnect both of the outer tie rod ends from the steering
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2004 Hummer H2
knuckles. Use your hands in order to move the tie rod ends. Are either of the tie rod ends abnormally
difficult to move? If yes, go to step 10 . If no, go to next step.
8. Inspect for binding ball joints. Use your hands to push and pull the steering knuckle inboard and
outboard. Are either of the steering knuckles abnormally difficult to move? If yes, go to step 11 . If no, go
to next step.
9. Inspect the wheel alignment and adjust as necessary. Refer to SPECIFICATIONS & PROCEDURES .
Did you complete the wheel alignment? After performing wheel alignment, go to step 13 .
10. Replace the outer tie rod end. After replacing tie rod end, go to step 13 .
11. Replace the damaged ball joint. Refer to Upper Control Arm Replacement or Lower Ball Joint
Replacement in Front Suspension. After repairs, go to step 13 .
12. Repair the steering column as necessary. Refer to Steering Column. After repairs, go to next step.
13. Operate the vehicle in order to verify the repair. Did you correct the condition? If yes, system is okay. If
no, go to step 3 .
NOISE DIAGNOSIS - FRONT SUSPENSION
DEFINITION: A loud bang or thump that can usually be felt and/or heard when the vehicle is driven over
bumps. This condition is commonly noticed when the vehicle trim height is too low.
2. Attempt to duplicate the condition. Road test the vehicle. Did you duplicate the condition? If yes, go to
next step. If no, system is okay.
3. Is the noise reactive to vehicle load or speed? If yes, go to next step. If no, go to step 7 .
4. Inspect the tires for proper tire Inflation and adjust as necessary. Inspect for unusual tire wear. Inspect the
wheel nuts for looseness and tighten as necessary. Did you find and correct the condition? If yes, go to
step 14 . If no, go to next step.
5. Inspect the front wheel bearings. Refer to WHEEL BEARING DIAGNOSIS . Did you find and correct
the condition? If yes, go to step 14 . If no, go to next step.
6. Inspect for front axle noises. Did you find and correct the condition? If yes, go to step 14 . If no, go to
next step.
7. Bounce the front of the vehicle in order to duplicate the noise. Did you duplicate the noise? If yes, go to
8. Raise and support the vehicle. Inspect the front suspension components for looseness. Inspect the front
suspension components for damage and repair as necessary. Did you find and correct the condition? If
yes, go to step 14 . If no, go to next step.
9. Install the J-39570 Chassis Ear or equivalent. See SPECIAL TOOLS . Bounce the front of the vehicle,
using the J-39570 or equivalent in order to locate the source of the noise. If necessary road test the
vehicle. Repair or replace any damaged components as necessary. Did you find and correct the condition?
If yes, go to step 14 . If no, go to next step.
10. Inspect the ball joints and steering components for lack of lubrication where applicable, looseness in the
ball joints, looseness in the steering linkage, or looseness in the tie rods. Did you find and correct the
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2004 Hummer H2
11. Inspect for damaged shock absorbers. Did you find and correct the condition? If yes, go to step 14 . If no,
go to next step.
12. Inspect the front stabilizer shaft and stabilizer shaft links for damage and repair as necessary. Did you
find and correct the condition? If yes, go to step 14 . If no, go to next step.
13. Inspect for control arm damage and repair as necessary. Did you find and correct the condition? If yes, go
to next step.
14. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If
no, go to step 3 .
NOISE DIAGNOSIS - REAR SUSPENSION
DEFINITION: Any noise emitted from the rear of the vehicle that is induced by VEHICLE SPEED or
DRIVING TERRAIN as related to the rear suspension.
2. Attempt to duplicate the condition. Road test the vehicle. Did you duplicate the condition? If yes, go to
next step. If no, system is okay.
3. Is the noise reactive to vehicle load or speed? If yes, go to next step. If no, go to step 6 .
4. Inspect and adjust the tire Inflation. Inspect for unusual tire wear. Inspect the wheel nuts for looseness.
Did you find and correct the condition? If yes, go to step 10 . If no, go to next step.
5. Inspect the rear axle for rear axle noises. Did you find and correct the condition? If yes, go to step 10 . If
no, go to next step.
6. Bounce the rear of the vehicle in order to duplicate the noise. Did you duplicate the noise? If yes, go to
7. Raise the vehicle. Inspect the rear suspension components for looseness and tighten as necessary. Inspect
the rear suspension components for damage and repair as necessary. Did you find and correct the
8. Inspect the rear shock absorber. Did you complete the inspection? If yes, go to step 10 . If no, go to next
step.
9. Install the J-39570 Chassis Ear or equivalent. See SPECIAL TOOLS . Bounce the rear of the vehicle,
using the J-39570 or equivalent, in order to locate the source of the noise. If necessary road test the
vehicle. Repair or replace any defective component as necessary. Did you find and correct the condition?
If yes, go to next step. If no, system is okay.
10. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If
no, go to step 3 .
POOR DIRECTIONAL STABILITY
DEFINITION: Driver is unable to maintain consistent, predictable vehicle driving control in any direction.
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2004 Hummer H2
2. Verify that the directional stability is poor. Does the system operate normally? If yes, system is okay. If
3. Inspect the front stabilizer fasteners for looseness. Inspect for damaged stabilizer bar, stabilizer bushings,
or damaged and missing stabilizer links. Did you find and correct the condition? If yes, go to step 10 . If
4. Inspect control arms, ball joints, and inner and outer tie rod ends for wear and damage. Did you find and
correct the condition? If yes, go to step 10 . If no, go to next step.
5. Inspect the wheel bearing. Did you find and correct the condition? If yes, go to step 10 . If no, go to next
step.
6. Inspect the vehicle trim height. Did you find and correct the condition? If yes, go to step 10 . If no, go to
next step.
7. Inspect the steering column for looseness. Did you find and correct the condition? If yes, go to step 10 . If
8. Inspect the steering gear mounting bolts for looseness. Did you find and correct the condition? If yes, go
to step 10 . If no, go to next step.
9. Inspect and adjust the wheel alignment as necessary. Did you complete the alignment? Go to next step.
no, go to step 3 .
RIDE DIAGNOSIS
2.
NOTE: Verify the vehicle suspension package RPO.
Verify that the ride is too soft or too hard. Does the vehicle ride normally? If yes, then system is okay. If
3. Inspect the tires for the proper inflation pressure. Is the tire inflation pressure correct? If yes, go to step 7 .
4. Inspect the vehicle trim height. Refer to TRIM HEIGHT INSPECTION PROCEDURE . Did you find
and correct the condition? If yes, go to step 7 . If no, go to next step.
5. Inspect the strut and shock absorbers. Refer to STRUTS OR SHOCK ABSORBERS ON-VEHICLE
TESTING . Inspect torsion bars and springs. Did you find and correct the condition? If yes, go to step 7 .
6. If equipped with the Air Suspension system refer to Air Suspension. Did you find and correct a
condition? If yes, go to next step. If no, system is okay.
7. Drive the vehicle in order to verify the repair. Did you correct the condition? If yes, system is okay. If no,
go to step 3 .
STRUTS OR SHOCK ABSORBERS ON-VEHICLE TESTING
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2004 Hummer H2

2. Verify that the customer's concern is present. Does the vehicle operate normally? If yes, system is okay.
3.
NOTE: A light film of oil on the top portion of the shock reservoir is normal.
Inspect each shock absorber for external fluid leakage. Is a strut or shock absorber leaking? If yes, go to
step 5 . If no, go to next step.
4. Use your hands in order to lift up and push down each corner of the vehicle 3 times. Remove your hands
from the vehicle. Locate a shock or strut that exceeds 2 cycles. Did you locate shock or strut that exceeds
2 cycles? If yes, go to next step. If no, go to step 6 .
5.
NOTE: Inspect the vehicle trim height in order to correct any possible causes of
shock/strut failures. Refer to TRIM HEIGHT INSPECTION PROCEDURE .
Replace the shock absorber. After replacing shock absorber, go to next step.
no, go to step 3 .
SUSPENSION BOTTOMS
DEFINITION: A loud bang or thump that can usually be felt and/or heard when the vehicle is driven over
bumps. This condition is commonly noticed when the vehicle trim height is too low.
2. Verify that the suspension bottoms. Does the vehicle operate normally? If yes, system okay. If no, go to
next step.
3. Check for vehicle overloading and correct the overloading condition as necessary. Did you find and
correct the condition? If yes, go to step 6 . If no, go to next step.
4. Inspect the shock absorbers, coil springs, and torsion bars for damage or wear and repair as necessary.
5. Inspect the vehicle trim height. Refer to TRIM HEIGHT INSPECTION PROCEDURE . Did you
complete the trim height inspection procedure? If yes, go to next step.
no, go to step 3 .
TRIM HEIGHT INSPECTION PROCEDURE
Trim Height Measurements
Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause
bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment
problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel
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2004 Hummer H2
alignment. Perform the following before measuring the trim heights:
1. Set the tire pressures to the pressure shown on the certification label.
2. Check the fuel level. Add additional weight if necessary to simulate a full tank.
3. Make sure the rear compartment is empty except for the spare tire.
4. Make sure the vehicle is on a level surface, such as an alignment rack.
Z Height Measurement
1. Lift the front bumper of the vehicle up about 38 mm (1.5 in).

2. Remove your hands.
3. Allow the vehicle to settle into position.
4. Repeat this jouncing operation 2 more times for a total of 3 times.
5. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in
order to obtain the Z height measurement (4). See Fig. 4 .
Fig. 4: Z Height Measurement

6. Push the front bumper of the vehicle down about 38 mm (1.5 in).
8. Allow the vehicle to rise.
9. Repeat the operation for a total of 3 times.
10. Measure the Z dimension.
11. Measure the Z dimension. The true Z height dimension number is the average of the high and the low
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2004 Hummer H2
measurements. See TRIM HEIGHT SPECIFICATIONS .
Z Height Adjustment
1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm
clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1)
into the nut increases the Z height by approximately 6.0 mm (0.2 in). See Fig. 5 .
Fig. 5: Z Height Adjustment

2. For vehicles without torsion bars, replace damaged or worn components as necessary.
D Height Measurement
NOTE: The D height dimension measurement determines the proper rear end ride
height. There is no adjustment procedure. Repair may require replacement of
suspension components.
1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 in).
3. Allow the vehicle to settle into position.
4. Repeat the jouncing operation 2 more times for a total of 3 times.
5. The D height is obtained by measuring the distance between the edge of the jounce cup along the jounce
bumper center line and the jounce pad on the rear axle. See Fig. 6 .
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2004 Hummer H2
Fig. 6: D Height Measurement

6. The true D height dimension number is the average of the high and the low measurements. Refer to
TRIM HEIGHT SPECIFICATIONS .
7. If these measurements are out of specifications, inspect for the following conditions:
z Sagging front suspension Refer to Torsion Bar Replacement in Front Suspension.
z Sagging rear coil springs Refer to COIL SPRING REPLACEMENT .
z Proper air suspension operation.
z Worn rear suspension components.
z Improper tire inflation.
z Improper weight distribution.
z Collision damage.
VEHICLE LEADS/PULLS
Definition: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at
the steering wheel to maintain the vehicle's straight path.
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2004 Hummer H2
2. Road test the vehicle in order to verify the complaint. Does the vehicle operate normally? If yes, system is
okay. If no, go to next step.
3. Inspect the tire/wheel assemblies for:
z Correct tire pressure.
z Correct tire size.
4. Perform the Radial Tire Lead/Pull Correction. Did you find and correct the condition? If yes, go to step
9 . If no, go to next step.
5. Inspect and correct/adjust the suspension and steering systems for the following conditions:
z Vehicle trim height. See TRIM HEIGHT INSPECTION PROCEDURE
z Excessively worn, loose, or damaged components.
6. Inspect the brake system for brake drag. With the vehicle suspended on a hoist, brake drag can be
identified by rotating each wheel several times and observing whether more force is need to rotate the left
wheel or the right wheel. Did you find and correct the condition? If yes, go to step 9 . If no, go to next
step.
7. Inspect the wheel alignment and adjust as necessary. Refer to SPECIFICATIONS . Did you correct the
8. Inspect the steering gear for unequal effort. The vehicle must be suspended on a hoist, the engine running,
and the transmission in park or neutral. Grasp the tire assembly and manually simulate a turn from the left
of center and the right of center observing whether more force is needed to turn to the left or to the right.
If this condition exists replace the steering gear. Did you correct the condition? If yes, system is okay. If
no, go to step 3 .
no, go to step 3 .
WHEEL BEARING DIAGNOSIS
2. Road test the vehicle in order to verify the customer's complaint. Does the vehicle operate normally? If
yes, system is okay. If no, go to next step.
3. Raise and support the vehicle. Inspect for tire or wheel damage. Did you find and correct the condition? If
yes, go to step 7 . If no, go to next step.
4. Install the J-39570 chassis ear. See SPECIAL TOOLS . Road test the vehicle to verify the location of
the wheel bearing noise. Did you locate the source of the wheel bearing noise? If yes, go to step 6 . If no,
go to next step.
5.
NOTE: If you are inspecting the FRONT wheel bearing/hub, support the front of
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2004 Hummer H2
the vehicle by the lower control arms in order to load the lower ball joint.
Raise and support the vehicle. Remove the wheel and tire. Mount and secure the J-8001 to the steering
knuckle. Firmly push the hub flange towards the vehicle. Ensure that the J-8001 contacts the vertical
surface of the hub flange as close as possible to the center of the flange. Firmly pull the hub flange away
from the vehicle. Inspect the total movement indicated by the J-8001. Is the measurement greater than
0.051 mm (0.002 in)? If yes, go to next step. If no, system is okay.
6. Replace the wheel bearing. Refer to FRONT SUSPENSION. After repairs, go to next step.
7. Road test the vehicle to verify the repair. Does the vehicle operate normally? If yes, system is okay. If no,
go to step 3 .
SPECIAL TOOLS
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2004 Hummer H2
Fig. 7: Dial Indicator Set (J-8001)

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2004 Hummer H2
Fig. 8: Chassis Ear (J-39570)

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2001 Kia Rio
2001 SUSPENSION Rear - Rio
2001 SUSPENSION
Rear - Rio
DESCRIPTION
The rear suspension system is the torsion beam axle type separated with spring and damper. The rear suspension
system works as follows : Suspension action is semi-independent, with the wheels carried on trailing arms,
rigidly connected to each other by a torsion beam. The beam provides positive control of trailing link alignment,
yet flexes in torsion to permit limited independent wheel action, and is welded with the lateral link at the beam
to prevent it from rolling. For isolation of road vibration, heavy rubber bushings are installed at the torsion
beam and trailing arm body brackets. Rubber insulators cushion the spring seats in the strut towers. See Fig. 1 .
Fig. 1: Identifying Rear Suspension Components

Courtesy of KIA MOTORS AMERICA, INC.
ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
Rear wheel alignment is not adjustable.
WHEEL BEARING
Helpmelearn Repair Manuals
Monday, April 17, 2006 5:22:47
5:22:43 PM Page 1 © 2004 Mitchell Repair Information Company, LLC.
2001 Kia Rio

2. Make sure the parking brake is fully released.
3. Remove the wheel and tire assembly.
4. Remove the grease cap.
5. Rotate the brake drum to make sure there is no brake drag. See Fig. 2 . If there is brake drag, increase the
brake shoe clearance then continue with bearing adjustments.
6. Seat the bearings by tightening the nut after raising the nut tap. Tighten nut to 18-21 ft. lbs. (25-29 N.m).
See Fig. 3 .
7. Loosen the nut slightly until it can be turned by hand.
8. Before the bearing preload can be set, the amount of seal drag must be measured and added to the
required preload.
9. Use a pull scale and measure the oil seal drag.
10. Pull the scale squarely. Take the oil seal drag value when the wheel hub starts to turn, and record it.
11. Proper bearing preload is attained by adding the oil seal drag measurement recorded in the previous step
to measurements taken while slowly turning the nut to adjust the bearing preload between 0.6-1.90 lbs.
(.26-.87 kg). See Fig. 4 .
12. After adjusting the preload, firmly fix the nut to the spindle groove.
13. Install the hub cap. See Fig. 5 .
14. Install the wheel and tire assembly. Tighten wheel lug nuts. See TORQUE SPECIFICATIONS .

Monday, April 17, 2006 5:22:43 PM Page 2 © 2004 Mitchell Repair Information Company, LLC.
2001 Kia Rio
Fig. 2: Testing Brake Drum Drag


2001 Kia Rio
Fig. 3: Seating Rear Wheel Bearings


2001 Kia Rio
Fig. 4: Measuring Bearing Preload


2001 Kia Rio
Fig. 5: Installing Hub Cap

REMOVAL & INSTALLATION

For exploded view of rear suspension components, See Fig. 21 .
COIL SPRING & SHOCK ABSORBER
Removal
1. Raise the rear of the vehicle and support it with safety stands after releasing the parking brake.
2. Remove the wheel and tire assemblies.
3. Install the jack under the torsion beam axle.
4. Loosen the rear shock absorber upper and lower bolts. See Fig. 6 .
5. Remove rear shock absorber.
2001 Kia Rio
6. Lower the jack slightly and remove the coil spring from the torsion beam axle. See Fig. 7 .
Installation
1. Install the coil spring onto the torsion beam axle and raise the jack slightly. See Fig. 7 .
2. Install the rear shock absorber and tighten the lower and upper bolts to specification. See Fig. 6 . For bolt
tightening specification, see TORQUE SPECIFICATIONS .
3. Remove the jack from under the torsion beam axle.
4. Install the wheel and tire assemblies. Tighten wheel lug nut to specification, see TORQUE
SPECIFICATIONS .
Fig. 6: Removing & Installing Rear Shock Absorber


2001 Kia Rio
Fig. 7: Removing & Installing Rear Coil Spring

LOWER TRAILING LINK & TRAILING LINK BUSHING
For exploded view of rear torsion beam axle and lower trailing link assemblies, see Fig. 21 .
Removal
4. Loosen the rear shock absorber lower bolt. See Fig. 6 .
5. Remove rear shock absorber.
6. Lower the jack slightly and remove the coil spring from the torsion beam axle. See Fig. 7 .
2001 Kia Rio
7. Remove the flexible hose clip and brake pipe from bracket. See Fig. 8
NOTE: Cover the brake pipe and flexible hose to prevent dust contamination and
leaking fluid.
8. Remove the flexible hose from the torsion beam axle.

9. Remove the parking brake cable bracket from the torsion beam axle. See Fig. 9
10. Release the backing plates and wheel spindle support after removing the brake backing plate and spindle
support assembly nuts from the back of each brake assembly. See Fig. 10 .
11. Remove the torsion beam trailing link flange bolts. See Fig. 11 .
12. Remove the lateral link tightening bolt and nut and remove the lateral link from the body. See Fig. 12 .
NOTE: Be careful not to damage the parking brake cable.
13. Remove the torsion beam axle.

14. Remove the rear shock absorber upper bolt.
15. Remove the spring upper seat bolt. See Fig. 13 .
16. Remove trailing link bushing using appropriate tool to press out bushing from the inboard side. See Fig.
14 .
Installation
NOTE: The arrow mark molded into the bushing face should be front side up. The
bushings may be lubricated with soapy water for easier installation. Do not use
oil or grease.
1. Position trailing link bushing on the outboard side of links with marks aligned parallel to the links axis.
Press in bushing with appropriate tool. See Fig. 15 .
2. Install the spring upper seat bolt. See Fig. 13 . For bolt tightening specification, see TORQUE
SPECIFICATIONS .
3. Install the rear shock absorber upper bolt. For bolt tightening specification, see TORQUE
SPECIFICATIONS .
4. Install the torsion beam axle. Install the lateral link onto the body and tighten nuts. See Fig. 12 . For bolt
tightening specification, see TORQUE SPECIFICATIONS .
5. Install the torsion beam trailing link flange bolts. See Fig. 11 . For nut tightening specification, see
TORQUE SPECIFICATIONS .
6. Install the brake backing plate and spindle support bolts onto each brake assembly and attach the backing
plates and wheel spindle support nuts. See Fig. 10 . For bolt\nut tightening specification, see TORQUE
SPECIFICATIONS .
7. Install the parking brake cable bracket onto the torsion beam axle. See Fig. 9 . For bolt tightening
specification, see TORQUE SPECIFICATIONS .
8. Install the flexible hose onto the torsion beam axle.
2001 Kia Rio
9. Install the brake pipe onto bracket and install flexible hose clip. See Fig. 8 .
10. Install the coil spring onto the torsion beam axle and raise the jack slightly. See Fig. 7 .
11. Install the rear shock absorber and tighten the lower bolt. See Fig. 6 . For bolt tightening specification,
see TORQUE SPECIFICATIONS .
13. Install the wheel and tire assemblies. For wheel lug nut tightening specification, see TORQUE
SPECIFICATIONS .
Fig. 8: Removing & Installing Brake Pipe & Flexible Hose Clip

2001 Kia Rio
Fig. 9: Removing & Installing Parking Brake Cable Bracket


2001 Kia Rio
Fig. 10: Removing & Installing Brake Backing Plate & Spindle Support Nuts

2001 Kia Rio
Fig. 11: Removing & Installing Flange Bolt & Nut


2001 Kia Rio
Fig. 12: Removing & Installing Lateral Link Bolt & Nut
Fig. 13: Removing & Installing Spring Upper Seat

2001 Kia Rio
Fig. 14: Removing Trailing Link Bushing


2001 Kia Rio
Fig. 15: Positioning Trailing Link Bushing

LATERAL LINK

2001 Kia Rio
Removal
4. Remove the lateral link bolt and nut from the body. See Fig. 12 .
5. Remove the lateral link nut from the torsion beam axle and remove the lateral link from vehicle.
Installation
1. Install the lateral link nut onto the torsion beam axle.
2. Install the lateral link bolt and nut onto the body. See Fig. 12
4. Install the wheel and tire assemblies. For wheel lug nut tightening specification, see TORQUE
SPECIFICATIONS .
WHEEL BEARING
For exploded view of rear spindle and bearing assemblies, see Fig. 20 .
Removal
1. Raise the rear of the vehicle and support it with safety stands.
3. Remove the hub cap.
4. Use a small cape chisel to raise the staked edge of the lock nut. See Fig. 16 .
NOTE: Use care not to damage the groove and threads of spindle.
5. Loosen rear axle lock nut. See Fig. 17 .

6. Remove the drum, washer and bearings as an assembly from the spindle.
NOTE: If it is difficult to remove the brake drum, adjust brake shoes to increase
the shoe clearance.
Installation
1. Install brake drum onto spindle. See Fig. 18 .
NOTE: Keep the drum centered on the spindle to prevent damage to the oil seal
and spindle threads.

2001 Kia Rio
2. Install the outer bearing and washer. See Fig. 19 .

3. Install new lock nut.
4. Adjust the bearing preload. See WHEEL BEARING . Under ADJUSTMENTS & INSPECTION.
5. Fix lock nut to the spindle groove firmly.
6. Install hub cap.
Fig. 16: Raising & Staking Rear Axle Lock Nut


2001 Kia Rio
Fig. 17: Loosening Rear Axle Lock Nut


2001 Kia Rio
Fig. 18: Installing Brake Drum Onto Spindle


2001 Kia Rio
Fig. 19: Installing Outer Bearing & Washer


2001 Kia Rio
Fig. 20: Exploded View Of Spindle & Bearing Assembly


2001 Kia Rio
Fig. 21: Exploded View Of Rear Suspension Components

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Brake Backing Plate & Spindle Support Bolt\Nut 32-45 (43-61)
Brake Pipe Bracket 10-17 (14-23)
Lateral Link-To-Body Bolts 58-72 (78-98)
Lateral Link-To-Torsion Beam Axle Bolts 58-72 (78-98)
Shock Absorber Bolt
Upper 27-40 (36-54)
Lower 58-72 (78-98)
Spring Upper Seat Bolt 27-40 (36-54)

2001 Kia Rio
Trailing Link Flange Bolts 72-87 (98-118)

Wheel Lug Nuts 65-87 (88-118)


General: 2001 Suspension Front - Rio

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General: 2001 Suspension Front - Rio

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2001 Kia Rio

2001 Suspension Front - Rio

Fig. 1: Front & Rear Suspension Service Tools

Fig. 2: Front & Rear Suspension System Troubleshooting Guide (1 Of 3)

Fig. 3: Front & Rear Suspension System Troubleshooting Guide (2 Of 3)

Fig. 4: Front & Rear Suspension System Troubleshooting Guide (3 Of 3)

DESCRIPTION & OPERATION

Fig. 5: Illustrating Front Suspension Components

INSPECTION & ADJUSTMENTS

NOTE: For alignment specifications and adjustments, see SPECIFICATIONS &

Fig. 6: Inspecting Coil Springs

Check the following points, repair or replace if necessary.

1. Loose installation bolts and nuts.

Fig. 7: Illustrating Lower Arm

Check the following points or replace if necessary.

1. Looseness of the installation bolts and nuts.

REMOVAL, DISASSEMBLY, INSPECTION, REASSEMBLY & INSTALLATION

Fig. 8: Illustrating Front Strut Assembly

1. Remove the clip of the strut side.

Fig. 9: Removing The Flexible Hose & ABS Sensor Cable

4. Detach the knuckle from the strut.

Fig. 11: Detaching The Knuckle From The Strut

5. Remove the attaching nut.

Fig. 12: Removing Strut From Tower

Fig. 13: Illustrating Front Strut Assembly Components

1. Secure the mounting block in a vise.

CAUTION: Use protective plates in the jaws of the vise

CAUTION: Do not remove the nut.

Fig. 14: Loosening The Piston Rod Nut

Fig. 15: Compressing The Coil Spring

4. Remove the strut nut and lock washer.

CAUTION: If replacing a spring, release the spring compressor progressively to

Fig. 16: Removing Coil Spring

Fig. 17: Releasing Spring Compressor Progressively

9. Before assembly, inspect the struts.

Check the following points, repair or replace if necessary.

1. Oil leakage or abnormal noise from the MacPherson strut.

Fig. 18: Inspecting Strut Assembly Components

Fig. 19: Compressing Coil Spring Assembly

6. Temporarily tighten strut rod nut by hand.

41-50 lb.ft (55-68 N.m, 5.6-6.9 kg.m)

Fig. 20: Tightening Strut Rod Nut

34-46 lb.ft (46-63 N.m, 4.7-6.4 kg.m)

Fig. 21: Installing Strut To Tower

76-90.4 lb.ft (103-123 N.m, 10.5-12.5 kg.m)

Fig. 22: Installing Strut Lower Mounting Bolts & Nuts

32-45 lb.ft (43-60.8 N.m, 4.4-6.2 kg.m).

Fig. 23: Installing The Stabilizer Control Link

Fig. 24: Installing Brake Line & ABS Sensor Cable

Fig. 25: Illustrating Lower Arm & Tension Rod Component

Fig. 26: Removing The Tension Rod Attaching Bolt

Fig. 27: Removing Tension Rod

Check the following points, replace if necessary.

1. Deformation or cracks in lower arm.

7.2-25.2 lb.ft (1.0-3.5 N.m, 10-35 kg.cm)

Pull scale reading :

2.2-7.7 lb (10-35 N, 1-3.5 kg)

Fig. 28: Measuring Ball Joint Rotation Torque

40-50 lb.ft (54-68 N.m, 5.5-6.9 kgm)

3. Tighten the lower arm frame bracket pivot bolt.

40-50 lb.ft (54-68 N.m, 5.5-6.9 kgm).

87-108 lb.ft (118-147 N.m, 12-15 kg.m)

FRONT STABILIZER BAR