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Front Suspension System: Removal & Installation Mazda RX-8 I рестайлинг

Suspension Front 26 illustrations ~1256 words

FRONT SHOCK ABSORBER AND COIL SPRING 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 the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove the front suspension tower bar. (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION [MT]»(ref-367617-S15466659542010072700000) .) (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION [AT]»(ref-367650-S42099286512010072700000) .)
  3. Remove in the order indicated in the table.
  4. Install in the reverse order of removal.
  5. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-367661-S19385474912010072700000) .)

Scheme 5

Scheme 5
Scheme 5

Piston Rod Nut Removal Note

WARNINGBefore removing the piston rod nut, secure the shock absorber and spring in the SSTs. Otherwise, the shock absorber and spring could fly off under tremendous pressure and cause serious injury or death, or damage to vehicle parts.

Scheme 6

Scheme 6
Scheme 6
  1. Install the coil spring to the SST using the following procedure. NOTE: Install the SST using a piece of clean rag to prevent the coil spring from being scratched. Set the SST attachments (tabs) to the positions shown in the figure. Install the front shock absorber and coil spring to the SST so that the coil spring is set to the position shown in the figure.
  2. Compress the coil spring using the SST .
  3. Remove the piston rod nut.

Scheme 7

Scheme 7
Scheme 7

Coil Spring Installation Note

  1. Protect the coil spring from scratches using a piece of cloth and install the SSTs .
  2. Compress the coil spring using the SSTs .
  3. 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

Upper Spring Seat Installation Note

  1. Align the mark on the upper spring seat with the dust boot projection.
  2. Install the upper spring seat so that the upper spring seat stud is at a 27°-33° angle to the shock absorber installation shaft (lower side.)

Scheme 9

Scheme 9
Scheme 9

FRONT UPPER ARM 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 table.
  2. Install in the reverse order of removal.
  3. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-367661-S19385474912010072700000) .)

Scheme 10

Scheme 10
Scheme 10

Caliper and Mounting Support Removal Note

  1. Remove the caliper and mounting support from the steering knuckle and suspend it with a cable in a location out of the way.

Shock Absorber Lower Bolt and Nut Removal Note

  1. Loosen the shock absorber upper nuts.
  2. Remove the front shock absorber lower bolt and nut.

Front Upper Arm Ball Joint Removal Note

  1. Remove the front upper arm ball joint from the steering knuckle using the SST .

Scheme 11

Scheme 11
Scheme 11

Front Upper Arm Removal Note

  1. Remove the front upper arm bolts.
  2. Push down the front lower arm, and then remove the front upper arm from the gap between the shock absorber lower end and the front lower arm.

Clip Installation Note

  1. Wipe the grease off the ball joint stud.
  2. Fill the inside of the new dust boot with grease.
  3. Install the dust boot on the ball joint.
  4. Install the clip using the SST .
  5. Verify that the clip is installed securely to the groove.
  6. Wipe off any excess grease.

Scheme 12

Scheme 12
Scheme 12

FRONT LOWER ARM 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 the front auto leveling sensor. (See «FRONT AUTO LEVELING SENSOR REMOVAL/INSTALLATION»(ref-367665-S29141800882010072700000) .)
  2. Remove in the order indicated in the table.
  3. Install in the reverse order of removal.

Scheme 13

Scheme 13
Scheme 13
  1. Remove the caliper and mounting support from the steering knuckle and suspend it with a cable in a location out of the way.

Front Lower Arm Ball Joint Removal Note

  1. Disconnect the front lower arm ball joint from the steering knuckle using the SST .

Note. When removing the front lower arm ball joint, the steering knuckle bushing may also come off. If it comes off, replace the steering knuckle.

Scheme 14

Scheme 14
Scheme 14

Upper Arm Ball Joint Removal Note

  1. Loosen the bolts on the vehicle side.
  2. Disconnect the upper arm ball joint using the SST .

Scheme 15

Scheme 15
Scheme 15

Bushing (Rear Side) Removal Note

  1. Mark the front upper arm as shown in the figure.
  2. Remove the bushing using the SSTs .

Scheme 16

Scheme 16
Scheme 16

Bushing (Front Side) Removal Note

CAUTIONBe careful not to damage the front lower arm. If it is damaged, replace it.
  1. Cut off the stopper plate rubber using a razor.
  2. Cut off 5-6 mm {0.20-0.23 in} from each side of the knob end of the bushing using a hacksaw.
  3. Remove the bushing using the SSTs .

Scheme 17

Scheme 17
Scheme 17

Bushing (Shock Absorber Lower Side Connecting Part) Removal Note

  1. Remove the bushing using the SSTs .

Scheme 18

Scheme 18
Scheme 18

Bushing (Shock Absorber Lower Side Connecting Part) Installation Note

  1. Compress the bushing using the SSTs so that the clearance distance A-B is 11.2-12.8 mm {0.441-0.503 in} .

Scheme 19

Scheme 19
Scheme 19

Bushing (Front Side) Installation Note

  1. Press the bushing in using the SSTs .
  2. Verify that there is no clearance between the bushing and the front lower arm.
  3. Insert the stopper plate rubber into the inner pipe of the bushing (front side.)

Scheme 20

Scheme 20
Scheme 20

Bushing (Rear Side) Installation Note

  1. Align the marks placed during removal and install the bushing.
  2. Press the bushing in using the SSTs so that the clearance distance A-B is 15.5-17.5 mm {0.611-0.688 in} .

Scheme 21

Scheme 21
Scheme 21
  1. Wipe the grease off the ball joint stud.
  2. Fill the inside of the new dust boot with grease.
  3. Install the dust boot to the ball joint.
  4. Install the clip using the SST .
  5. Verify that the clip is installed securely to the groove.
  6. Wipe off any excess grease.

Scheme 22

Scheme 22
Scheme 22

Front Lower Arm Installation Note

  1. Install the front lower arm rear side bushing part horizontally.
  2. Install the front lower arm front side bushing part.

FRONT STABILIZER 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 the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-367654-S32712849732010072700000) .)
  2. Slightly bend back the front mudguard, and remove the aerodynamic under cover. (See «AERODYNAMIC UNDER COVER REMOVAL/INSTALLATION»(ref-367654-S38607773612010072700000) .)
  3. Remove in the order indicated in the table.
  4. Install in the reverse order of removal.

Scheme 23

Scheme 23
Scheme 23

Stabilizer Bracket Installation Note

  1. Apply rubber grease to the inner side of the stabilizer bushing.
  2. Align the outer side of the stabilizer slide stopper with the stabilizer bushing.
  3. Install the stabilizer bracket.

Scheme 24

Scheme 24
Scheme 24

FRONT CROSSMEMBER 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 the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove the front suspension tower bar. (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION [MT]»(ref-367617-S15466659542010072700000) .) (See «FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION [AT]»(ref-367650-S42099286512010072700000) .)
  3. Remove the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-367654-S32712849732010072700000) .)
  4. Slightly bend back the front mudguard, and remove the aerodynamic under cover. (See «AERODYNAMIC UNDER COVER REMOVAL/INSTALLATION»(ref-367654-S38607773612010072700000) .)
  5. Remove the front auto leveling sensor. (See «FRONT AUTO LEVELING SENSOR REMOVAL/INSTALLATION»(ref-367665-S29141800882010072700000) .)
  6. Remove the under cover.
  7. Remove the transverse member. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-367650-S41899597552010072700000) .)
  8. Remove in the order indicated in the table.
  9. Install in the reverse order of removal.
  10. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-367661-S19385474912010072700000) .)
  11. Set the EPS system to the neutral position. (See «EPS SYSTEM NEUTRAL POSITION SETTING»(ref-367652-S07879882872010072700000) .)

Scheme 25

Scheme 25
Scheme 25
CAUTIONAfter disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction.

Scheme 26

Scheme 26
Scheme 26

Axle And Hub Component Removal Note

  1. Loosen the front upper arm inner bolts.
  2. Remove the axle and hub component.

Mounting Rubber Removal Note

  1. Suspend the engine using the SSTs .
  2. Support the front crossmember using a jack. WARNING: Verify that the crossmember component is securely supported by a jack. If the crossmember component falls, it could cause serious injury or death, or damage to the vehicle.
  3. Remove the transverse member.
  4. Remove the mounting rubber while gradually lowering the front crossmember.

Scheme 27

Scheme 27
Scheme 27

FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION [MT]

  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove in the order indicated in the table.
  3. Install in the reverse order of removal.

Scheme 28

Scheme 28
Scheme 28

Plate Installation Note

  1. Install the plates with the identification marks facing upward.

Scheme 29

Scheme 29
Scheme 29

FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION [AT]

  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION [13B-MSP]»(ref-367623-S37771794152010072700000) .)
  2. Remove in the order indicated in the table.
  3. Install in the reverse order of removal.

Scheme 30

Scheme 30
Scheme 30
  1. Install the plates with the identification marks facing upward.

TRANSVERSE MEMBER REMOVAL/INSTALLATION

  1. Remove the under cover.
  2. Remove the transverse member.
  3. Install the transverse member.
  4. Install the under cover.

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