Front Suspension: Removal & Installation Mazda 5 I

FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION

Scheme 4

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the front wheel alignment and adjust it if necessary. (See «FRONT WHEEL ALIGNMENT»(ref-244340-S19110530852006092100000) ).

Scheme 5

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 7

1. Install the shock absorber and coil spring so that the positioning projection on the mounting rubber is aligned with the positioning hole on the body.
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 8

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

Piston Rod Nut Removal Note

Scheme 9

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 10

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 11

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

Scheme 12

Scheme 13

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.

Front Lower Arm Removal Note

Note. 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. (See «ENGINE REMOVAL/INSTALLATION [L3]»(ref-244325-S22618102452006092100000) ).
2. Move the engine and transaxle slightly towards the front side of the vehicle using a jack.
3. Remove the front lower arm rear side bolt.
4. Remove the front lower arm.

Scheme 14

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

1. Temporarily install the front lower arm.
2. Install the No.1 engine mount. Tightening torque 93.1-116.6 Nm {9.50-11.88 kgf. m, 68.67-85.99 ft. lbf}
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 15

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. Front lower arm rotational torque 1.0-4.9 N.m {11-49 kgf. cm, 9-43 in. lbf} Pull scale reading [10-49 N {1.1-4.9 kgf, 3-10 lbf}]

Scheme 16

1. Detach the steering shaft. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION»(ref-244338-S20307144292006092100000) ).
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Inspect the wheel alignment and adjust it if necessary. (See «FRONT WHEEL ALIGNMENT»(ref-244340-S19110530852006092100000) ).

Scheme 17

1. Support the front crossmember using a jack.
2. Remove the front crossmember brackets.

Scheme 18

1. Detach the silencer hangers on the middle pipe from the front crossmember.
2. Lower the front crossmember slowly approx. 90 mm {3.5 in} and remove the front stabilizer component.

Scheme 19

1. Verify the installation direction of the stabilizer bracket (the arrow should point to the front) by placing the stabilizer bar so that the identification mark faces the left side of the vehicle.
2. Install the stabilizer bushings and brackets so that they contact the stabilizer stoppers.

Scheme 20

1. With the arrow on the stabilizer bracket facing the vehicle front, tighten the bolts.

Scheme 21

1. Remove the stabilizer control link from the vehicle.
2. Inspect for bending or damage. If there is any malfunction, replace the stabilizer control link.
3. Rotate the ball joint stud 10 times and shake it side to side 10 times.
4. Measure the ball-joint rotational torque using an Allen wrench and a torque wrench. Front stabilizer control link ball joint rotational torque 0.2-0.9 N.m {3-9 kgf. cm, 2-7 in. lbf} If not within the specification, replace the stabilizer control link.

FRONT CROSSMEMBER REMOVAL/INSTALLATION

Scheme 22

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the wheel alignment and adjust it if necessary. (See «FRONT WHEEL ALIGNMENT»(ref-244340-S19110530852006092100000) ).

Scheme 23

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

Scheme 24

1. Remove the front crossmember, front stabilizer, lower arm, and steering gear as a single unit using a transmission jack.

Scheme 25

Scheme 26

Scheme 27

1. Verify the left and right identification marks and install the positioning SST to the front crossmember. NOTE: Verify the identification marks before installation because the left and right parts of the SST have different shapes.
2. Support the front crossmember, front stabilizer, lower arm, and steering gear and linkage using a transmission jack.
3. Raise the transmission jack gradually and install the front crossmember to the vehicle. At this point verify that the SST is securely inserted in the positioning holes on the body.
4. Tighten the front crossmember installation bolts and nuts. NOTE: When installing the No.1 engine mount, tighten the bolts in order shown in the figure to prevent abnormal noise and vibration after assembly.