manual pajero 4x4 front suspention.docx

8/11/2019 manual pajero 4x4 front suspention.docx

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33A-1

FRONT

SUSPENSIONCONTENTS 33209000202

GENERAL INFORMATION . . . . . . . . . . . . . . . . . .2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . .4

Front WheelAlignment Check andAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . 6

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . .2

SEALANTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3SHOCKABSORBER AND UPPERARM . . . . .7

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . .3

LOWERARMAND TORSION BAR . . . . . . . . .11

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 15


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33A-2 FRONT SUSPENSION General Information/Service Specifications

GENERAL INFORMATION

Thefrontsuspensionisanindependentsuspension

33200010259

having the double wishbone combined withtorsion bar spring.

the

TORSIONBAR

CONSTRUCTION DIAGRAM

Torsion bar

Upperarm

Shockabsorber Knuckle

Stabilizer bar

Lowerarm

SERVICE

SPECIFICATIONS 33200030156

Items Standardvalue Limit

Toe-in Atthecentreoftyrethreadmm 07

Toe-angle(perwheel) 0016'

Toe-out

angle

on

turns(innerwheelwhenouterwheelat20)

2118'

Camber 040'30'(Differencebetweenrightandleftwithin30')

Caster 240'

100'

(Difference

betweenrightandleftwithin30')

Kingpinangle 1450'

Shockabsorberattachingdimensionmm 12

UpperarmballjointstartingtorqueNm 0.83.4

Lowerarmballjointendplaymm 0.3

Stabilizerlinkassemblyattachingdimensionmm 68

Items Specifications

LengthxO.D.mm 1,308x27


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33A-3FRONT SUSPENSION Sealants/Special Tools

SEALANTS 33200050022

SPECIAL

TOOLS 33200060148

Tool Number Name Use

MB991113 orMB990635

Steeringlinkagepuller Upperorlowerarmballjointdisconnection

MB990968 Torquewrench Upperarmballjointrotationtorquemeasurement

MB990326 Preloadsocket

MB991522 Torsion bar bushingremoverandinstaller

Lower arm bushing (A) removal andpress-fitting

MB990883 Rear

suspension

bushingarborLower

arm

bushing

(B)

removal

and

press-fitting

A MB990957

A:MB990971

Lower arm bushingremoverandinstallerA:Base

Item Specifiedsealant

Upperballjointdustcovertoupperballjointgroove 3MATDPartNo.8661orequivalent

Stopperbolt 3MStudLockingPartNo.4170orequivalent


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33A-4 FRONT SUSPENSIONOn-vehicle Service

ON-VEHICLE SERVICE 33100090274

FRONT WHEELALIGNMENT CHECKANDADJUSTMENT

Measure the wheel alignment with the vehicle parked on alevel surface.The front suspension, steering system, and wheels shouldbeservicedtonormalconditionpriortomeasurementofwheelalignment.

TOE-IN

Standard value:At the centre of tyre tread 0 7mmToe angle (per wheel) 0 016'

1. If the toe-in is not within the standard value, adjust thetoe-in by turning the left and right tie rod turnbucklesby the same amount (in opposite directions).

Caution(1) Take care when turning the tie rod end's outerside, as the threads are reversed.

(2) Make sure that the left/right differenceof the tierod does not exceed 5mm.

NOTEThe toe will move out as the left turnbuckle is turnedtoward the front of the vehicle and the right turnbuckleis turned toward the rear of the vehicle.

2. Use a turning radius gauge to check that the steeringangle is at the standard value. (Refer to GROUP 37A On-vehicle Service.)

TOE-OUTANGLE ON TURNS

To check the steering linkage, especially after the vehiclehasbeeninvolvedinanaccidentorifanaccidentispresumed,it isadvisable tocheck the toe-outangleon turns inadditionto the wheel alignment.Conductthistestonthe leftturnaswellasontherightturn.

Standard value:

2118' (inner wheel when outer wheel at 20)

Outside:L.H. thread

Inside:R.H.

thread


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33A-5FRONT SUSPENSIONOn-vehicle Service

CAMBERAND CASTER

Standard value:

Camber 040'30'(Differencebetween right and leftwithin

30')

Caster 240' 100' (Difference between right andleft within 30')

If the standard value is not obtained, make adjustment bythe following procedure.

1. Loosen the upper arm mounting bolts and nuts.

NOTERemove theshockabsorbermountingnutand locknut,compresstheshockabsorberand loosentheupperarmmounting bolts and nuts.

2. Increase or decrease shims between upper arm shafandcrossmembertoadjustthecamberandcaster.(Refe to Charts for Shim Increase or Decrease.)

Caution(1) Difference in shim thickness between front and

rear must be 4 mm or less.(2) Do not use 4 or more shims at one location.

Adjustmentofshim

Part

number Thickness

mm

MR132525 1

MR132526 2

MB176288(Front

shim

integral

with

rear

shim)1

MB176289(Frontshimintegralwithrearshim)

2

MR132525 orMR132526

MB176288 orMB176289


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33A-6 FRONT SUSPENSION On-vehicle Service

Charts for Shim Increase or Decrease

HOW TO USE CHARTS EXAMPLETo decrease camber by 30' and caster by 40',increase combined front side shim thickness by

These charts show how shimsremoved from existing shims.

are added to or

3 mm and increase combined rear side shimthickness

Increase infrontsideshim

thickness

mm

by 2 mm.

Decrease in rear side Increase inrearsideshimshim thicknessmm thicknessmm

:Camber adjusting angle:Caster adjusting angleDecrease in front side

shim thicknessmm

KINGPIN INCLINATION

Standard value: 1450'

BALL JOINT DUST COVER CHECK

1. Check the dustcover forcracksor damage bypushingit with finger.

2. If the dust cover is cracked or damaged, replace lowerarmballjointassemblyorupperarmballjointassembly.

NOTECracksordamageofthedustcovermaycausedamageof the balljoint.

33200860106


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33A-7FRONT SUSPENSION Shock Absorber and Upper Arm

SHOCKABSORBER AND UPPERARM

REMOVALAND INSTALLATION

Caution

33200250118

*: Indicates parts which should be temporarily tightened,the ground in an unladen condition.

and then fully tightened with the vehicle on

15 Nm

98 118 Nm

84

95 3

71

6 59 88 Nm

3 44 Nm2

15 Nm10 Nm 4

88 103 Nm*

Removal steps

}D]}C]

1.

Shock

absorber 6.

Speed

sensor

bracket

}B] 7. Rebound stopper

8. Shims

10. Upper arm balljoint assembly

bracket clearance adjustment]A} 2. Rear anchor arm adjusting nut

3. Brake hose connection4. Hose clip5. Upper arm balljoint connection

]C}}A] 9. Upper arm

]B}

10

Sealant: 3M ATD Part No.8661 or equivalent

25 Nm

10

Post-installation

Operation

Press thedustcoverwitha finger tocheckwhetherthe dust cover is cracked or damaged.

Brake Fluid Supplying Brake Line Bleeding

(Refer to GROUP 35A On-vehicle Service.)

Front Wheel Alignment Check and Adjustment(Refer to P.33A-4.)

Pre-removal

Operation

Brake Fluid Draining


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33A-8 FRONT SUSPENSION Shock Absorber and Upper Arm

REMOVAL SERVICE POINTS

]A}REARANCHORARMADJUSTING NUTLOOSENING

Loosen the anchor arm bolt of the torsion bar all the way.

CautionWhen the rear anchor armadjustingnut is loosened,use

a

jack

to

support

the

lower

arm

of

the

side

to

be

loosened.

]B}UPPERARM BALL JOINT DISCONNECTION

Usespecialtools todisconnect theupperarmballjointfromthe knuckle.

Caution1. Support special tool with a cord, etc. to prevent it

from coming off.2. Only loosen themountingnut, do not remove it from

the ball joint.

]C}SHIMS REMOVAL

NOTEThe camber and caster adjustment shims should be keptfor use during assembly.

INSTALLATION SERVICE POINTS

}A]UPPERARM INSTALLATION

Install the upper arm so that the OUT mark on the upperarm shaft is facing toward the outside of the vehicle.

}B]REBOUND STOPPER INSTALLATION

Install the rebound stopper so that its arrow faces insideof the vehicle.Inside ofvehicle

Mark

MB990635 orMB991113

Nut

Cord

Balljoint


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33A-9FRONT SUSPENSION Shock Absorber and Upper Arm

}C]BUMP STOPPERAND BUMP STOPPERBRACKET CLEARANCE ADJUSTMENT

1. With the vehicle in an unladen condition, dimensionfromthebumpstoppertothebumpstopperbracketshouldbe 18 mm.

NOTEDimensionAwillbe(B=50mm)whenthebumpstoppe

is

a

new

part.

When

the

bump

stopper

is

worn

and

becomes less than 50 mm, dimensionA will increaseby the decreased amount.

2. IfdimensionA isnot18 mm,adjust the rearanchorarmadjusting nut.

}D]SHOCKABSORBER INSTALLATION

Install the shock absorber so that the distance (A) shownin the illustration is at the standard value.

Standard value (A): 1 2mm

INSPECTION 33200260074

UPPERARM BALL JOINT BREAKAWAY TORQUECHECK

1. After shaking the upper arm balljoint assembly studseveral times, install the nut to the stud and use thespecialtooltomeasurethebreakawaytorqueoftheuppe arm balljoint assembly.

Standard value: 0.8 3.4 Nm

When the measuredvalue exceeds the standardvalue,replace

the

upper

arm

ball

joint.When the measured value is lower than the standar value, check that the balljoint turns smoothly withou excessive play. If not, it is possible to use that upperarm balljoint.

2.

3.

MB990968

MB990326

A

Bump stopperbracket

A

Bump Bstopper


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33A-10 FRONT SUSPENSION Shock Absorber and Upper Arm

UPPERARM BALL JOINT DUST COVER CHECK

1. Press thedustcoverwitha finger tocheckwhether thedust cover is cracked or damaged.

2. If dust cover iscracked or damaged, replace the upperarmballjoint.Crackedordamageddustcovermaycausedamage to the balljoint. In addition, if the dust coverisdamagedduringservicework, replace thedustcover.

UPPERARM BALL JOINT DUST COVERREPLACEMENT 33200800092

Onlywhendustcoverisdamagedaccidentallyduringservicework, replace the dust cover as follows:

1. Applymultipurposegreasetotheinteriorofthedustcoverand the upper arm balljoint.

Apply the specified sealant to the balljoint groove andsecure the dust cover to the upper arm balljoint with

ring.

Specified

sealant:3MATD Part No. 8661 or equivalent

Press thedustcoverwitha finger tocheckwhether thedust cover is cracked or damaged.

2.

3.

Ring


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33A-11FRONT SUSPENSION Lower Arm and TorsionBar

LOWERARMAND TORSION BAR

REMOVALAND INSTALLATION

Caution

33200280117

*: Indicates parts which should be temporarily tightened,the ground in an unladen condition.

and then fully tightened with the vehicle on

88 103 Nm*

44 Nm5 Nm 2

14118 177 Nm* 6127

10137 157 Nm*53

137 157 Nm* 6 7 5106 Nm

15

62

Nm

11

14813

25 Nm9 12 Nm

81 Nm

Removal

steps

}B] Bump stopper and bump stopperbracket clearance adjustment

1. Heat protector (right side only)2. Anchor arm assembly adjusting nut

}A] 3. Rear anchor arm assembly}A] 4.Torsion bar

5. Anchor collar6. Heat cover (right side only)7. Dust covers

]A} 8. Lower arm balljoint connection9. Stabilizer bar connection

10. Bump stopper11. Lower arm shaft

}A] 12. Front anchor arm13. Lower arm14. Lower arm balljoint assembly15. Stopper bolt

1414

15

Sealant: 3M Stud Locking 4170 orequivalent

Anchorbolt

3

7 47

Post-installation

Operation

Press thedustcoverwitha finger tocheckwhetherthe dust cover is cracked or damaged.

Front Wheel Alignment Check and Adjustment(Refer to P.33A-4.)

Under Cover and Skid Plate Installation

Pre-removal

Operation

Under Cover and Skid Plate Removal


12/16

33A-12 FRONT SUSPENSION Lower Arm and TorsionBar

REMOVAL SERVICE POINT

]A}LOWERARM BALL JOINT DISCONNECTION

Usespecial tools todisconnect the lowerarmballjoint fromthe knuckle.

Caution1. Support special tool with a cord, etc. to prevent it

from coming off.

2. Only

loosen

the

mounting

nut,

do

not

remove

it

from

the ball joint.

INSTALLATION SERVICE POINTS

}A]FRONTANCHORARM/TORSION BAR/REARANCHORARM INSTALLATION

1. Check the identificationmarksat the end of the left andright torsion bars.

Rfor right sideLfor left side

When installing the torsion bar, align the white mark on

the

serrated

section

of

the

torsion

bar

with

the

matingmark on the anchor arm.

2.

3. Mount the anchor bolt as shown in the illustration, andinstall the rear anchor arm adjusting nut.

Anchorbolt

Rearanchorarm

Matingmark Frontanchorarm

ificationmark

wmarkMating

mark

Rearanchor armassembly

mark

Matingmark

Iden

Whiteoryello

Identification

Matingmark

MB991113 orMB990635

Nut

Cord

Balljoint


13/16

33A-13FRONT SUSPENSION Lower Arm and TorsionBar

}B]BUMP STOPPERAND BUMP STOPPERBRACKET CLEARANCE ADJUSTMENT

1. With the vehicle in an unladen condition, dimensionAfromthebumpstoppertothebumpstopperbracketshouldbe 18 mm.

NOTEDimensionAwillbe18mm(B=50mm)whenthebump

stopper

is

a

new

part.

When

the

bump

stopper

is

worn

andbecomeslessthan50mm,dimensionAwillincreaseby the decreased amount.

2. If dimensionA is not 18 mm, adjust the anchor armassembly adjusting nut.

INSPECTION

LOWERARM BALL JOINT END PLAY

Checkthelowerarmballjointassemblyendplaybyfollowingthe steps below.1. Measure the lowerarmballjointassemblyendplaywith

a dial indicator.

Limit: 0.3mm

2. If the lower arm balljoint assembly end play exceeds

the

limit,

replace

the

lower

arm

ball

joint

assembly.

33200290080

LOWERARM BALL JOINT DUST COVER CHECK

1. Press thedustcoverwitha finger tocheckwhether thedust cover is cracked or damaged.

2. When dust cover is cracked or damaged, replace thelower arm balljoint assembly.

NOTEIf the dust cover is cracked, the ball joint could bedamaged, so if the dust cover is damaged duringmaintenance work, replace it.

REAR LOWERARM BUSHING REPLACEMENT33200810149

1. Using the special tool, remove the lower arm bushing(A) from the bracket.

NOTEWhen removing the left hand rear lower arm bushing,detach the differential carrier. (Refer to GROUP 26Differential carrier.)

MB991522

Bump stopperbracket

A

Bump Bstopper


14/16

33A-14 FRONT SUSPENSION Lower Arm and TorsionBar

2. Using the special tool, press-fit the lower arm bushing(A) into the bracket.

NOTEInstall the rear lowerarm bushing in the direction shown inthe illustration.

FRONT LOWERARM BUSHINGREPLACEMENT 33200810156

1. Remove the front lowerarmbushing fromthe lowerarmby using special tools.

2. Coat the front lowerarmbushingand the lowerarmwithsoap solution and press-fit the front lower arm bushin into the lowerarmbyusingspecial toolsand takingcar not to twist or tilt the front lower arm bushing.

NOTEPress-fit the front lower arm bushing again from theoppositesidetoequalizebushingprojectionsatbothends.

LOWERARM BALL JOINT DUST COVERREPLACEMENT 33200820104

Onlywhendustcoverisdamagedaccidentallyduringservicework, replace the dust cover as follows:

1. Applymultipurposegreasetotheinteriorofthedustcoverand the lower arm balljoint.Secure the dust cover to the lower arm balljoint withring.Press thedustcoverwitha finger tocheckwhether thedust cover is cracked or damaged.

2.

3.

MB990971

MB990883

MB990883

MB990971

Frontofvehicle

MB991522


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33A-15FRONT SUSPENSION Stabilizer Bar

STABILIZER BAR 33200400063

REMOVAL AND INSTALLATION

6

5

4 2

3 112 Nm

12 Nm

Removal steps

Stabilizer linkassemblymountingnutadjustment

1. Stabilizer bracket (A)2. Bushing

}A] 3. Stabilizer bracket4. Bushing5. Stabilizer

bar6. Stabilizer link assembly

INSTALLATION SERVICE POINT

}A]STABILIZER LINKASSEMBLY MOUNTING NUTADJUSTMENT

Tighten thenutso that thedimensionAshown in the figureis at the standard value.

Standard value (A): 6 8mm

Pre-removal and Post-installationOperation Under Cover and Skid Plate Removal and

Installation


16/16

NOTES

manual pajero 4x4 front suspention.docx

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