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Front Suspension: Removal & Installation Mazda 3 BK

Suspension Front 22 illustrations ~833 words

REMOVAL/INSTALLATION

CAUTIONPerforming the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled while servicing the vehicle.
  1. Remove in the order indicated in the illustration.
  2. Install in the reverse order of removal.
  3. Inspect the total wheel alignment if necessary. See «WHEEL ALIGNMENT»(ref-177429) .

Scheme 5

Scheme 5
Scheme 5

Shock Absorber & Coil Spring Removal Note

  1. Loosen the front lower arm inner bolt.
  2. Separate the shock absorber from the wheel hub, steering knuckle component by tapping the upper part of the steering knuckle with a hammer.

Scheme 6

Scheme 6
Scheme 6

Piston Rod Nut Removal Note

WARNINGBefore removing the piston rod nut, secure the shock absorber and coil spring in the SSTs. Otherwise, the coil spring could fly off under tremendous pressure and cause serious injury or death, or damage to vehicle parts.
  1. Install the shock absorber and coil spring to the SSTs using a piece of cloth in order to prevent the coil spring from being scratched.
  2. Compress the coil spring using the SSTs and remove the piston rod nut.

Scheme 7

Scheme 7
Scheme 7

Coil Spring Installation Note

  1. Compress the coil spring using the SSTs.
  2. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring seat.

Scheme 8

Scheme 8
Scheme 8

Dust Boot Installation Note

Install the dust boot by hooking the bottom edge over the shock absorber lip.

Scheme 9

Scheme 9: Dust Boot Installation Note
Scheme 9: Dust Boot Installation Note

Scheme 10

Scheme 10: Bearing Installation Note
Scheme 10: Bearing Installation Note
  1. Install the bearing by hooking the upper end of the dust boot to the bearing lip.
  2. Align the projection A on the lower part of the shock absorber with the bearing projection B.

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12: Shock Absorber & Coil Spring Installation Note
Scheme 12: Shock Absorber & Coil Spring Installation Note
  1. Align the piston rod nut with the center of the part where the shock absorber is installed by positioning the piston rod nut with lengths A all the same, and tighten the shock absorber upper bolts.
  2. Align the knuckle notch with projection A on the lower side of the shock absorber.
  3. Raise the front lower arm using a jack and install the shock absorber and coil spring.

Scheme 13

Scheme 13
Scheme 13

Stiffener Installation Note

Install the stiffener so that the mark (RH or LH) faces upward.

Scheme 14

Scheme 14: Stiffener Installation Note
Scheme 14: Stiffener Installation Note

Front Lower Arm Removal Note

Note. When working on the right side of vehicles, move the engine and transaxle slightly towards the front side of the vehicle so that the engine does not interfere with the removal of the lower arm rear side bolt.

  1. Remove the No.1 engine mount center bolt.
  2. Move the engine and transaxle slightly towards the front side of the vehicle.
  3. Remove the front lower arm rear side bolt.
  4. Remove the front lower arm.

Scheme 15

Scheme 15: Dust Boot Installation Note
Scheme 15: Dust Boot Installation Note
  1. Wipe the grease off the ball stud.
  2. Fill the inside of the new dust boot with grease.
  3. Press the boot onto the ball joint using the SST.
  4. Wipe away the excess grease.

Front Lower Arm Installation Note

CAUTIONInstall the front lower arm according to the following procedures for optimal installation. Tighten the lower arm installation bolt properly when the vehicle is lifted.
  1. Temporarily install the front lower arm.
  2. Install the No.1 engine mount. Tightening torque 68.67-85.99 ft. lbs. (93.1-116.6 N.m).
  3. Tighten the front lower arm rear side bolt.
  4. Tighten the front lower arm front side bolt.
  5. Tighten the nut (front lower arm ball joint).

Scheme 16

Scheme 16: FRONT LOWER ARM INSPECTION
Scheme 16: FRONT LOWER ARM INSPECTION
  1. Remove the lower arm from the vehicle.
  2. Inspect the arm for bending or damage, and the ball joint for excessive looseness. If there is any malfunction, replace the lower arm.
  3. Rotate the ball joint stud 5 times. Install the SST to the ball joint stud, measure the rotational torque using a pull scale. If not within the specification, replace the lower arm. Rotational torque 9-43 inch lbs. (1.0-4.9 N.m). Pull scale reading 3-10 lbs. (10-49 N).
  1. Detach the steering shaft from the steering gear and linkage.
  2. Remove in the order indicated in the illustration.
  3. Install in the reverse order of removal.
  4. Inspect the wheel alignment and adjust it if necessary. See «WHEEL ALIGNMENT»(ref-177429) .

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18: Front Crossmember Bracket Removal Note
Scheme 18: Front Crossmember Bracket Removal Note
  1. Support the front crossmember using a jack.
  2. Remove the front crossmember brackets.

Scheme 19

Scheme 19: Front Stabilizer Component Removal Note
Scheme 19: Front Stabilizer Component Removal Note
  1. Detach the silencer hangers on the middle pipe from the front crossmember.
  2. Lower the front crossmember slowly approximately 3.5" (90 mm) and remove the front stabilizer component.

Scheme 20

Scheme 20: Stabilizer Bracket Removal Note
Scheme 20: Stabilizer Bracket Removal Note
  1. Secure the stabilizer bracket flange using a vise.
  2. Remove the front stabilizer.

Scheme 21

Scheme 21: Stabilizer Bushing Installation Note
Scheme 21: Stabilizer Bushing Installation Note
  1. Verify the installation direction of the stabilizer bushing.
  2. Widen the stabilizer bushing opening 0.7-1.0" (16-26 mm) and install the bushing to the front stabilizer as shown in the illustration.

Scheme 22

Scheme 22
Scheme 22

Stabilizer Bracket Installation Note

  1. Apply grease to the stabilizer bushing.
  2. Install the stabilizer bracket using a vise.

Scheme 23

Scheme 23
Scheme 23

Front Stabilizer Component Installation Note

Tighten the bolts in order indicated in the illustration.

Scheme 24

Scheme 24: Front Stabilizer Component Installation Note
Scheme 24: Front Stabilizer Component Installation Note
CAUTIONPerforming the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, disconnect the ABS wheel-speed sensor wiring harness connector (axle side) and fix the wiring harness to an appropriate place where it will not be pulled by mistake while servicing the vehicle.

Scheme 25

Scheme 25
Scheme 25
  1. Remove in the order indicated in the illustration.
  2. Install in the reverse order of removal.
  3. Inspect the wheel alignment and adjust it if necessary. See «WHEEL ALIGNMENT»(ref-177429) .

Tie-Rod End Ball Joint Removal Note

  1. Remove the tie-rod end locknut.
  2. Detach the tie-rod end from the steering knuckle using the SST.

Scheme 26

Scheme 26
Scheme 26

P/S Angle Sensor Connector Removal Note

  1. Remove the coolant reserve tank.
  2. Disconnect the P/S angle sensor connector.

Front Crossmember Component, Steering Gear and Linkage Component Removal Note

Remove the front crossmember, front stabilizer, lower arm, and steering gear as a single unit using a transmission jack. (Scheme 18)

Front Crossmember Component, Steering Gear and Linkage Component Installation Note

Install the front crossmember, front stabilizer, lower arm, and steering gear as a single unit using a transmission jack. (Scheme 18)

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