Front Strut / Shock Tower: Service and Repair
Damper
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
3. Remove road wheel.
4. Remove clip securing brake hose to bracket on damper.
5. Release ABS sensor harness and brake hose from damper.
6. Release ABS sensor from hub.
7. Remove 2 bolts securing brake caliper to hub. Release caliper from hub and tie aside.
CAUTION: Do not allow caliper to hang on brake hose.
8. Remove nut securing track rod to steering arm and break taper joint using LRT-57-043.
9. Remove upper nut from anti-roll bar link, release link and position aside.
CAUTION: Use a spanner and an Allen key to prevent ball joint rotating when undoing link.
10. Remove 2 nuts and bolts securing hub to damper.
11. Release damper from hub.
12. LH side: Remove 2 bolts securing positive and negative leads to fusebox.
13. LH side: Disconnect multiplug from engine compartment fuse box.
14. LH side: Release leads and position aside.
15. LH side: Remove 3 nuts securing fusebox and position fusebox aside.
16. RH side: Remove bolt securing coolant reservoir and position reservoir aside.
17. Reference mark top mounting in relationship to body.
18. Remove 3 nuts from damper top mounting and remove spring and damper assembly.
19. Position a suitable spring compressor in vice.
20. Position spring and damper assembly to spring compressor. Compress spring.
CAUTION: Note alignment of top mounting, spring and damper dust cover.
21. Compress spring by 2 to 3 cm until loose, hold damper shaft with Allen key, remove and discard mounting plate nut.
22. Remove rebound washer and mounting plate.
23. Remove spring aid and bump plate.
24. Remove spring seat, dust cover and bump stop cup.
25. Remove damper from spring.
26. Release and remove spring from compressor.
Refit
1. Inspect damper, spring mounting rubbers and bearing for deterioration and damage.
2. Clean mating faces of spring, mounting and mounting plate.
3. Clean damper shaft and bump stop plate.
4. Position spring and damper assembly to spring compressor. Compress spring.
5. Fit damper to spring, ensure spring locates in cut recess in damper plate.
6. Fit bump cup, bump stop and dust cover to damper.
7. Fit spring aid and bump plate.
8. Fit mounting plate and rebound washer.
9. Using new nut, hold damper shaft with Allen key and tighten nut to 57 Nm (42 ft. lbs.).
CAUTION: Note alignment of top mounting, spring and damper dust cover.
10. Release and remove spring from compressor.
11. Clean mating face of top mounting plate.
12. Position damper assembly and align top mounting to body, fit nuts and tighten to 45 Nm (33 ft. lbs.).
13. LH side: Position fusebox, fit nuts and tighten to 8 Nm (6 ft. lbs.).
14. LH side: Connect positive and negative leads, fit bolts and tighten to 8 Nm (6 ft. lbs.).
15. LH side: Connect multiplug to fusebox.
16. RH side: Position coolant reservoir and secure with bolt.
17. Fit hub to damper, fit nuts and bolts and tighten to 205 Nm (151 ft. lbs.).
18. Clean anti-roll bar link taper and mating face.
19. Connect anti-roll bar link, fit new nut and tighten to 55 Nm (41 ft. lbs.).
CAUTION: Use a spanner and an Allen key to prevent ball joint rotating when undoing link.
20. Clean track rod taper and mating face.
21. Connect track rod end to steering arm using new nut and tighten nut to 55 Nm (41 ft. lbs.).
22. Clean ABS sensor, smear sensor with an anti-seize grease and fit sensor to hub.
CAUTION: Ensure ABS sensor is fully located into hub, so that sensor touches pole wheel teeth.
23. Position ABS harness and brake hose in bracket and secure with clip.
24. Fit road wheel(s) and tighten nuts to 115 Nm (85 ft. lbs.).
25. Remove stand and lower vehicle.
26. Connect battery earth lead.