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Front Suspension: Removal & Installation Subaru BRZ ZC

Suspension Front 34 illustrations ~2412 words

Installation

  1. Installation of front strut tower bar LH Using a new bolt and three new nuts, install the front strut tower bar LH. Standard value: T=16N.m {163kgf.cm} {11.8ft.lbf}
  2. Installation of front strut tower bar RH NOTE: Service the RH side in the same procedure as the LH side.

Scheme 3

Scheme 3: Component
Scheme 3: Component

Scheme 4

Scheme 4
Scheme 4

Removal

Note. The following servicing procedures are for the RH side. Service the LH side in the same procedure as the RH side.

Scheme 5

Scheme 5: Removal
Scheme 5: Removal

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Removal of front tire
  2. Disconnection of speed sensor FR RH Remove the two clamps, and remove the speed sensor FR RH.
  3. Disconnection of front flexible hose No. 1 Remove the bolt, and disconnect the front flexible hose No. 1 from the front shock absorber w/coil spring.
  4. Disconnection of front stabilizer link ASSY RH Secure the stud bolt and remove the nut. Disconnect the front stabilizer link ASSY RH from the front shock absorber w/coil spring.
  5. Removal of front suspension support dust cover RH NOTE: If the front shock absorber w/coil spring must be disassembled, remove the front suspension support dust cover RH. Remove the front suspension support dust cover RH.
  6. Removal of front shock absorber w/coil spring Support the front suspension lower arm ASSY RH with a garage jack. Remove the two bolts and two nuts, and disconnect the front shock absorber w/coil spring from the steering knuckle RH. Remove the three nuts of the front suspension support SUB-ASSY RH. Remove the front shock absorber w/coil spring from the vehicle.

Note. The following procedure is for LH side. Service the LH side and the RH side using the same procedure.

  1. Installation of front shock absorber w/coil spring Using three new nuts, install the front shock absorber w/coil spring (upper side). Standard value: T=23N.m {235kgf.cm} {17.0ft.lbf} Using the two bolts and two new nuts, install the shock absorber w/coil spring to the steering knuckle LH. CAUTION: Insert the bolts from the rear of the vehicle. Standard value: T=155N.m {1581kgf.cm} {114.3ft.lbf}
  2. Installation of front stabilizer link ASSY LH Install the front stabilizer link ASSY LH to the shock absorber w/coil spring. Secure the stud bolt and install the part with a new nut. Standard value: T=46N.m {469kgf.cm} {33.9ft.lbf}
  3. Installation of front flexible hose No. 1 Using a bolt, install the front flexible hose No. 1 to the shock absorber w/coil spring. Standard value: T=33N.m {337kgf.cm} {24.3ft.lbf}
  4. Installation of front suspension support dust cover LH Install the front suspension support dust cover LH on the shock absorber w/coil spring.
  5. Installation of speed sensor FR LH Install the two clamps of the wiring harness for the speed sensor FR LH on the shock absorber w/coil spring.
  6. Installation of front tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}
  7. Stabilization of vehicle Lower and remove the jack, and bounce the vehicle several times to stabilize the front suspension.
  8. Inspection and adjustment of front wheel alignment (Refer to «FRONT WHEEL ALIGNMENT»(ref-619173-S12285229782014053000000) )
  9. Headlight adjustment (Refer to «ADJUSTMENT»(ref-619164-S02642911452014060900000) )
  10. Mid point setting of the VDC sensor (Refer to «WORK SUPPORT»(ref-619151-S00270732952014053000000) )

Scheme 12

Scheme 12: Disposal
Scheme 12: Disposal
  1. Disposal of shock absorber ASSY FR LH Secure the shock absorber ASSY FR LH in a vertical position. Press down on the piston rod with hands by approximately 70mm {2.756in}. Using a saw, etc., slowly make a hole in the section shown in the figure to purge the gas. CAUTION: Wear protective eye wear. Since the gas pressure may spray metal chips, perform the procedure by covering the saw with a piece of cloth, etc. NOTE: Gas to be released is colorless, odorless, and harmless.

Scheme 13

Scheme 13: Components
Scheme 13: Components

Scheme 14

Scheme 14
Scheme 14

Note. The following procedure is for LH side. Service the RH side in the same procedure as the LH side. Removal of front tire Removal of undercover front AL (Refer to REMOVAL ) Removal of undercover COMPL T/M (Refer to REMOVAL )

Scheme 15

Scheme 15: Removal
Scheme 15: Removal

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. 4. Removal of lower arm support plate Remove the bolt and nut, and remove the lower arm support plate.
  2. 5. Disconnection of tie-rod end SUB-ASSY LH (Refer to «REMOVAL»(ref-619162-S38866174092014053000000) )
  3. 6. Disconnection of steering knuckle LH (Refer to «REMOVAL»(ref-619162-S38866174092014053000000) )
  4. 7. Removal of stabilizer link ASSY LH (Refer to «REMOVAL»(ref-619174-S37109925182014053000000) )
  5. 8. Removal of front suspension lower arm ASSY LH Remove the bolt and nut, and remove the front suspension lower arm ASSY LH.
  6. 9. Removal of front suspension lower arm bolt Using the SST, remove the front suspension lower arm bolt. SST 20299AG020

Scheme 18

Scheme 18: Disassembly
Scheme 18: Disassembly

Scheme 19

Scheme 19
Scheme 19
  1. Removal of front lower arm bushing No. 1 LH Using the SST, remove the front lower arm bushing No. 1 LH. SST 20299AG000, 20299AG010
  2. Removal of front lower arm bushing No. 2 LH Using the SST, remove the front lower arm bushing No. 2 LH. SST 927680000

Scheme 20

Scheme 20: Inspection
Scheme 20: Inspection

Scheme 21

Scheme 21
Scheme 21
  1. Inspection of front suspension lower arm ASSY LH Rotation inspection of ball joint Check that there is no play by moving the upper and lower portions of front tire in an axial direction with the brake pedal depressed. If there is play, replace the front suspension lower arm ASSY LH. Check that there is no play by moving the upper and lower portions of front tire in an axial direction with the brake pedal released. If there is play, replace the front axle hub. Place the nut on the stud of the lower arm. Vibrate and turn the stud. Criteria: There is no abnormal interference or play during vibration and turning. If there is abnormal interference or play during vibration and turning, replace the front suspension lower arm ASSY LH. Dust cover inspection Check the dust cover for cracks or grease leakage. If there are cracks or grease leakage on the dust cover, replace the front suspension lower arm ASSY LH.

Scheme 22

Scheme 22: Assembly
Scheme 22: Assembly

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. Installation of front lower arm bushing No. 1 LH Using the SST, install the front lower arm bushing No. 1 LH in the front suspension lower arm ASSY LH so that the dimensions are within the range shown in the figure. SST 20299AG000, 20299AG010
  2. Installation of front lower arm bushing No. 2 LH Using the SST, install the front lower arm bushing No. 2 LH in the front suspension lower arm ASSY LH. SST 927680000

Note. The following procedure is for LH side. Service the RH side in the same procedure as the LH side.

  1. Installation of front suspension lower arm bolt Using the SST, install a new front suspension lower arm bolt. SST 20299AG020 Standard value: T=110N.m {1122kgf.cm} {81.1ft.lbf}
  2. Temporary tightening of front suspension lower arm ASSY LH Temporarily tighten the part using the bolt and a new nut. CAUTION: Insert the bolt from the front of the vehicle.
  3. Installation of steering knuckle LH With a nut, install the front suspension lower arm ASSY LH to the steering knuckle LH. Standard value: T=51N.m {520kgf.cm} {37.6ft.lbf}
  4. Installation of tie-rod end SUB-ASSY LH (Refer to «INSTALLATION»(ref-619162-S40605366862014053000000) )
  5. Temporary tightening of lower arm support plate Using a new bolt and nut, install the lower arm support plate. Standard value: T=110N.m {1122kgf.cm} {81.1ft.lbf}
  6. Installation of stabilizer link ASSY LH (Refer to «INSTALLATION»(ref-619174-S31258688532014053000000) )
  7. Installation of front tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}
  8. Stabilization of vehicle (Refer to «INSTALLATION»(ref-619174-S41418137432014053000000) )
  9. Final tightening of front suspension lower arm ASSY LH Fully tighten the bolts and nuts. Standard value: T=85N.m {867kgf.cm} {62.7ft.lbf}
  10. Installation of undercover COMPL T/M (Refer to «INSTALLATION»(ref-619189-S26330443752014053000000) )
  11. Installation of undercover front AL (Refer to «INSTALLATION»(ref-619189-S26330443752014053000000) )
  12. Inspection and adjustment of front wheel alignment (Refer to «FRONT WHEEL ALIGNMENT»(ref-619173-S12285229782014053000000) )
  13. Headlight adjustment. (Refer to «ADJUSTMENT»(ref-619164-S02642911452014060900000) )
  14. Mid point setting of the VSC (VDC) sensor (Refer to «WORK SUPPORT»(ref-619151-S00270732952014053000000) )

Scheme 25

Scheme 25: Components
Scheme 25: Components

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27: Removal
Scheme 27: Removal

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. Removal of front tire
  2. Removal of undercover front AL (Refer to «REMOVAL»(ref-619189-S01819081472014053000000) )
  3. Removal of undercover COMPL T/M (Refer to «REMOVAL»(ref-619189-S01819081472014053000000) )
  4. Removal of undercover front side rear LH Remove the three clips and remove the undercover front side rear.
  5. Removal of undercover front side rear RH NOTE: Remove the part in the same manner as LH side.
  6. Removal of front stabilizer link ASSY LH Secure the stud bolt and remove the nut. Remove the front stabilizer link ASSY LH from the front shock absorber w/coil spring. Secure the stud bolt and remove the nut. Remove the front stabilizer link ASSY LH from the stabilizer bar FR.
  7. Removal of front stabilizer link ASSY RH NOTE: Service the RH side in the same procedure as the LH side.
  8. Removal of sub frame COMPL LH Remove the four bolts, and remove the sub frame COMPL LH with the stabilizer bar FR.
  9. Removal of sub frame COMPL RH NOTE: Service the RH side in the same procedure as the LH side.
  10. Removal of front stabilizer bracket No. 2 LH Remove the bolt and nut, and remove the front stabilizer bracket No. 2 LH.
  11. Removal of front stabilizer bracket No. 2 RH NOTE: Service the RH side in the same procedure as the LH side.
  12. Removal of stabilizer bar FR Remove the stabilizer bar FR.
  13. Removal of front stabilizer bar bushing No. 1 (installed on LH side) Remove the front stabilizer bar bushing No. 1 (installed on LH side) from the stabilizer bar FR.
  14. Removal of front stabilizer bar bushing No. 1 (installed on RH side) NOTE: Service the RH side in the same procedure as the LH side.

Scheme 31

Scheme 31: Inspection
Scheme 31: Inspection
  1. Inspection of front stabilizer link ASSY LH Inspection of ball joint Using aluminum plate, secure the front stabilizer link ASSY LH in a vise. Install the mounting nut on the stud of the front stabilizer link ASSY LH. Vibrate and turn the stud. Criteria: There is no abnormal interference or play during vibration and turning. If there is abnormal interference or play during vibration and turning, replace the front stabilizer link ASSY LH. Dust cover inspection Check the dust cover for cracks or grease leakage. If there are cracks or grease leakage on the dust cover, replace the front stabilizer link ASSY LH.

Scheme 32

Scheme 32: Installation
Scheme 32: Installation

Scheme 33

Scheme 33
Scheme 33
  1. Installation of front stabilizer bar bushing No. 1 (installed on LH side) Install the front stabilizer bar bushing No. 1 on the outer side of the vehicle than the ring section of the stabilizer bar FR. CAUTION: Install the front stabilizer bar bushing No. 1 with the arrow mark facing the front of the vehicle.
  2. Installation of front stabilizer bar bushing No. 1 (installed on RH side) NOTE: Service the RH side in the same procedure as the LH side.
  3. Installation of front stabilizer bracket No. 2 LH Using the bolt and nut, install the front stabilizer bracket No. 2 LH on the sub frame complete LH. Standard value: Bolt T=75N.m {765kgf.cm} {55.3ft.lbf} Nut T=25N.m {255kgf.cm} {18.4ft.lbf}
  4. Installation of front stabilizer bracket No. 2 RH NOTE: Service the RH side in the same procedure as the LH side.
  5. Installation of sub frame COMPL LH Using four new bolts, install the stabilizer bar FR with the sub frame complete (body mounting cushion SUB-ASSY RR) LH. Standard value: T=60N.m {612kgf.cm} {44.3ft.lbf}
  6. Installation of sub frame COMPL RH NOTE: Service the RH side in the same procedure as the LH side.
  7. Installation of front stabilizer link ASSY LH Secure the stud bolt, and install the front stabilizer link ASSY LH to the stabilizer bar FR with a new nut. Standard value: T=46N.m {469kgf.cm} {33.9ft.lbf} Secure the stud bolt, and install the front stabilizer link ASSY LH to the front shock absorber w/coil spring with a new nut. Standard value: T=46N.m {469kgf.cm} {33.9ft.lbf}
  8. Installation of front stabilizer link ASSY RH NOTE: Service the RH side in the same procedure as the LH side.
  9. Installation of undercover front side rear LH Install the undercover front side rear LH with the three clips.
  10. Installation of undercover front side rear RH NOTE: Service the RH side in the same procedure as the LH side.
  11. Installation of undercover COMPL T/M (Refer to «INSTALLATION»(ref-619189-S26330443752014053000000) )
  12. Installation of undercover front AL (Refer to «INSTALLATION»(ref-619189-S26330443752014053000000) )
  13. Installation of front tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}
  14. Stabilization of vehicle (Refer to «INSTALLATION»(ref-619174-S41418137432014053000000) )
  15. Inspection of front tires in straight-ahead position
  16. Inspection and adjustment of front wheel alignment (Refer to «FRONT WHEEL ALIGNMENT»(ref-619173-S12285229782014053000000) )
  17. Headlight adjustment. (Refer to «ADJUSTMENT»(ref-619164-S02642911452014060900000) )
  18. Mid point setting of the VSC (VDC) sensor (Refer to «WORK SUPPORT»(ref-619151-S00270732952014053000000) )

Scheme 34

Scheme 34: Components
Scheme 34: Components

Scheme 35

Scheme 35: Removal
Scheme 35: Removal
  1. Installation of engine hanger (Refer to «REMOVAL»(ref-619184-S27168385372014053000000) )
  2. Removal of front suspension lower arm ASSY LH (Refer to «REMOVAL»(ref-619174-S34722937552014053000000) )
  3. Removal of front suspension lower arm ASSY RH NOTE: Service the RH side in the same procedure as the LH side.
  4. Disconnection of front stabilizer link ASSY LH (Refer to «REMOVAL»(ref-619174-S03132501932014053000000) )
  5. Disconnection of front stabilizer link ASSY RH NOTE: Service the RH side in the same procedure as the LH side.
  6. Removal of sub frame COMPL LH (Refer to «INSPECTION»(ref-619174-S04508333312014053000000) )
  7. Removal of sub frame COMPL RH NOTE: Service the RH side in the same procedure as the LH side.
  8. Removal of steering gear ASSY (Refer to «REMOVAL»(ref-619175-S41770416172014053000000) )
  9. Removal of front crossmember SUB-ASSY Remove 2 nuts from the front crossmember SUB-ASSY. Remove the four bolts, and remove the front crossmember SUB-ASSY.

Scheme 36

Scheme 36: Installation
Scheme 36: Installation
  1. Installation of front crossmember SUB-ASSY Install four new bolts in the order shown in the figure to temporarily install the front crossmember SUB-ASSY. Temporarily attach two nuts to the front crossmember SUB-ASSY. Fully tighten the four bolts. Standard value: T=95N.m {969kgf.cm} {70.1 ft.lbf} Fully tighten the two nuts. Standard value: T=45N.m {459kgf.cm} {33.2ft.lbf}
  2. Adjustment of shift lever position (automatic transmission) CAUTION: If the mounting bolts of the front crossmember SUB-ASSY have become even slightly loose, check the adjustment of the shift lever. (Refer to «ADJUSTMENT»(ref-619159-S17502888692014053000000) )
  3. Installation of steering gear ASSY (Refer to «INSTALLATION»(ref-619175-S06339191022014053000000) )
  4. Installation of sub frame COMPL LH (Refer to «INSTALLATION»(ref-619174-S31258688532014053000000) )
  5. Installation of sub frame COMPL RH NOTE: Service the RH side in the same procedure as the LH side.
  6. Installation of front stabilizer link ASSY LH (Refer to «INSTALLATION»(ref-619174-S31258688532014053000000) )
  7. Installation of front stabilizer link ASSY RH NOTE: Service the RH side in the same procedure as the LH side.
  8. Installation of front suspension lower arm ASSY LH (Refer to «INSTALLATION»(ref-619174-S30292939772014053000000) )
  9. Installation of front suspension lower arm ASSY RH NOTE: Service the RH side in the same procedure as the LH side.
  10. Removal of engine hanger (Refer to «REMOVAL»(ref-619184-S27168385372014053000000) )
  11. Inspection and adjustment of front wheel alignment (Refer to «FRONT WHEEL ALIGNMENT»(ref-619173-S12285229782014053000000) )
  12. Mid point setting of the VDC sensor (Refer to «WORK SUPPORT»(ref-619151-S00270732952014053000000) )

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