Haima M3. Chassis System. Service Manual - part 2

 

List of tires and drive shafts 2B-7 

 

sleeve 

Note:  the dustproof rubber sleeves are different 
from each other on wheel side and transmission 
drive axle side; apply the specified grease supplied 
in kits of dustproof rubber sleeve. 

1.  Apply the specified grease to the dustproof 

rubber sleeve on wheel side. 

Filling capacity: 90-110 g {3.13- 3.82oz} 

2.  Since the spline of shaft has been wrapped 

with a taper during the removal, the dustproof 
rubber sleeve can be mounted at this time. 

3. Remove 

the 

tape. 

Keypoints for assembling 3-foot universal joint 

1.  nstall 3-foot universal joint with a crowbar 

and hammer by aligning to the mark; 

 

2.  Install the new stop ring with clip forceps. 

Keypoints for assembling outer ring 

Note: apply the specified grease supplied in kits of 
dustproof rubber sleeves. 

1.  Apply the specified grease to the outer ring 

and transmission drive axle side dustproof 
rubber sleeve; 

Filling capacity of grease:130-140g {4.59-4.95oz} 

2.  Assemble the outer ring; 

3.  Wrap the head of screwdriver with a cloth, 

then lift up the small end of each dustproof 
rubber sleeve carefully, and drain the air 
remaining in dustproof rubber sleeve. 

 

Keypoints for assembling the transmission drive 
axle side dustproof rubber sleeve clamp 

Note:  the new hoop must be used every time. The 
wrapping direction of hoop should be reverse to 
forward rotation direction of drive shaft. 

1.  After wrapping the hoop by a turn, clamp it 

with clip forceps; 

2.  Lock the hoop with a locking clamp; 

 

 

Keypoints for assembling the dustproof rubber 
sleeve clamp on wheel side 

1.  Turn SST adjusting bolt to adjust the 

clearance A. 

Clearance A:2.9 mm {0.11 in} 

 

2.  Lock the small dustproof rubber sleeve clamp 

on wheel side with SST, and ensure the 
clearance B conforms to the provisions for 
technical requirements. If the clearance B 
exceeds the specified value, reduce the 
clearance A of SST, and re-lock the dustproof 
rubber sleeve. If the clearance B is below the 
specified value, replace the dustproof rubber 
sleeve clamp, increase the clearance A of SST, 
and lock the new dustproof rubber sleeve; 

Clearance B: 2.4-2.8 mm 

 

{0.095-0.110 in} 

3.  Ensure the dustproof rubber sleeve clamp 

shall not be outside the clip mounting area. If 

Adjusting screw 

 

List of tires and drive shafts 2B-8 

 

any of above cases occurs, replace the hoop, 
and repeat Steps 2 and 3; 

4.  Fill in the dustproof rubber sleeve with the 

grease supplied in repair kits; 

5.  Turn SST adjusting bolt to adjust the 

clearance A. 

Clearance A: 3.2 mm {0.13 in}; 

6.  Lock the big dustproof rubber sleeve clamp 

on wheel side with SST; 

7.  Ensure the clearance B conforms to the 

provisions for technical requirements; 

If the clearance B exceeds the specified value, 
reduce the clearance A of SST, and re-lock the 

dustproof rubber sleeve. If the clearance B is 
below the specified value, replace the dustproof 
rubber sleeve clamp, increase the clearance A of 
SST, and turn the edges of new dustproof rubber 
sleeve up to clearance B: 2.4-2.8 mm {0.095-0.110 
in}; 

8.  Ensure the dustproof rubber sleeve clamp is 

not outside the hoop mounting area. If any of 
above cases occurs, replace the hoop, and 
repeat Steps 7 and 8.  

 

 

 

 

Wheels and tires 2C-1 

 

Chapter 12 

Wheels and tires 

 

Description and operation ......................................................................................................................2C-2 

Tires and wheels................................................................................................................................ 2C-2 

Tread ................................................................................................................................................. 2C-2 

Buffer layer ....................................................................................................................................... 2C-2 

Tire body ........................................................................................................................................... 2C-2 

Tire bead ........................................................................................................................................... 2C-2 

Tire tube ............................................................................................................................................ 2C-2 

Sidewall of tire .................................................................................................................................. 2C-2 

Tire .................................................................................................................................................... 2C-2 

Tire hydroplaning.............................................................................................................................. 2C-2 

Standing wave ................................................................................................................................... 2C-3 

Tire rotation....................................................................................................................................... 2C-3 

All season tire.................................................................................................................................... 2C-3 

Tire label ........................................................................................................................................... 2C-3 

Spare tire ........................................................................................................................................... 2C-3 

Wheel ................................................................................................................................................ 2C-3 

Tire pressure...................................................................................................................................... 2C-3 

Tire rotation....................................................................................................................................... 2C-4 

Wheel balance ................................................................................................................................... 2C-4 

Diagnostic data and procedures.............................................................................................................2C-4 

Tire wears.......................................................................................................................................... 2C-4 

Repair instructions ............................................................................................................................ 2C-6 

Instructions........................................................................................................................................ 2C-7 

 

 

 

 

Wheels and tires 2C-2 

 

Description and operation 

Tires and wheels 

Tread 

The portion contacting the road surface outside the 
buffer layer and tire body. It’s made of high wear-
resistant rubber. Its operation is determined by its 
surface details. 

Buffer layer 

The fabric layer between the tread and tire body is 
used to prevent the damages of tires caused by 
road impacts and vibration. 

Tire body 

This main portion is a tire-like structure consisting 
of high-strength synthetic fiber cord fabric. Since it 
must maintain the tire pressure and bear all the 
loads and vibrations of tires, so it must have high 
fatigue-resistant properties. 

Tire bead 

The steel wire coil on ends of tire body, which is 
covered with rubber layers and wrapped with 
nylon threads. It’s used to fix the tire on the rim.

 

Tire tube 

The most tires applied in modern vehicles are 
tubeless tires. 

Sidewall of tire 

It’s used to protect the tire body, flexing resistant 
and improve the driving comfort. 

Tire 

Structure of tubeless tire 

 

 

 

 

185

Width (mm)

 

60

Flatness rate 60% 

(Height/width)×100

 

R

 

Radial tire

 

15

Rim diameter 

(Inner diameter of tire, feet)

84

Max. load index

 

185/60R1

5 

84H

 

H

 

Max. speed rating

 

Tire hydroplaning 

When the vehicle is driving on the road surface 
with water at high speed, it will make the tires 
unable to drive like rolling on the good road 
surface, thus the tires may float on it. This is called 
as tire hydroplaning.It will cause the failure of 
brake, low friction force and steering failure, so 
it’s very dangerous.  

 

High-speed driving

Low-speed driving

Buffer layer

 

Tread

Sidewall 

Tire body

Tire bead

Inflating 

valve

Width

Outer 

diameter

Inner 

diameter

 

Height

Width

 

Wheels and tires 2C-3 

 

Standing wave 

During the rotation of tires, the tread will produce 
the repeated deformations and restoring torques. 
However, the new deformation has been produced 
and the previous deformation still exists at higher 
speed, so a vibration wave will be produced on 
local part of tread. The lower the tire pressure is, 
the more serious its vibration wave is, especially at 
high speed. 

 

 

Tire rotation 

As indicated in the tire performance criteria (TPC), 
the numbers have been engraved in the tire side 
mold near to tire size. It indicates that these 
numbers include the traction force index, strength, 
size and rolling resistance conforming to the 
criteria. Generally speaking, each size of tire shall 
have different TPC numbers.  

Note:  Don’t use different types of tires on the 
same vehicle, e.g.radial tire and bias tire, except in 
emergency cases, because the vehicle will be 
seriously influenced, and it may cause the control 
failure of vehicle.  

Replace the original tires with the tires of the same 
size, load and structure. The use of other sizes or 
structures of tires will seriously influence the ride 
comfort, steering properties, speedometer / 
mileometer values, vehicle ground clearance, and 
clearance from tire to vehicle body or chassis. But 
it’s not applicable for spare tires. 

It’s recommended to replace a pair of tires on the 
same shaft synchronously during the renewal of 
tires. 

If it’s required to replace a tire, find a nearest tread 
to compensate the braking coefficients. 

Different producers design different tread patterns, 
but the same TPC number may be used on the 
same vehicle. 

 

All season tire 

Now, most of vehicles are equipped with all season 
PCR tires as standard configurations. These tires 
can be used as snow tires. During the use in the 
snow, their average ratio is 37% higher than 
friction coefficient of non-all season tires. In other 
aspects, e.g.their wet water friction coefficient, 
rolling resistance, tread service life and air 
resistance are all improved, because the design of 
tread patterns and tread compound are also 
improved. These tires have “M+S” engraved 
behind their tire side marked size codes. The suffix 
“MS” is also engraved behind the instructions for 
tire side TPC numbers. 

Not all the steering wheel tires are all season tires. 
These tires have no “MS” marks behind the tire 
sizes or behind the instructions for TPC numbers. 

Tire label 

The tire labels shall be permanently affixed behind 
the side door of driver’s seat, and the tires shall be 
inflated as per the above tire pressure. The 
maximum vehicle load, tire specifications 
(including the spare tire) and inflating pressure 
((including the spare tire) are described on the tire 
labels.  

Spare tire 

This vehicle is equipped with full-size wheels and 
spare tires on it. 

Wheel 

If any of the following cases occur to the wheels, 
they must be replaced: bends, indentions, flanging 
or deflected jumps, air leakage of weld joints, 
enlargement of bolt holes, or fixing failure or 
serious rusting of bolts. The jumps of wheel 
transition will cause the vibration of vehicle. Any 
replaced wheel must have the same load, diameter, 
rim width, offset distance and mounting size as 
those of original wheel. The inconformity of wheel 
size or type will influence the service life of wheel 
and bearing, cooling of brake, readings of 
speedometer/kilometer, vehicle ground clearance, 
and clearance from tire to vehicle body and chassis. 

Tire pressure 

The recommended air pressure of any vehicle tire 
shall be carefully calculated, which will give your 
driving/ride comfort, good steering ability, extend 
the service life of tire, and ensure its loading 
capacity. 

Check the tire every 5,000km. The tire pressure 
must be checked every month or before driving it 
for long distance. The tire must be checked at low 

 

Wheels and tires 2C-4 

 

temperature, i.e. when the vehicle drives for about 
3 minutes or at less than 1. 6km/hour. Inflate the 
tire as per the air pressure indicated in the tire label 
on driver’s seat side door. The inflation pressure of 
tire has been given in “Instructions for Tire 
Specifications and Inflation Pressure” of this 
section.  

The inflating valve must have a nut cap on it, 
which is used to prevent the dust and water from 
entering into it.  

The air pressure above the recommended pressure 
will lead to: 

●

  Harder ride and driving 

●

  Explosion or damages of tire 

●

  Rapid wears of tread in the middle of tire  

The air pressure below the recommended pressure 
will lead to: 

●

  Large noises while turning 

●

 Difficult 

steering 

●

  Rapid or uneven wears of both sides of tire 

●

  Scratches or cutting of tire edges 

●

  Fracture of tire cord 

At higher tire temperature, its different tire 
pressure on the same shaft will lead to: 

●

 Uneven 

braking 

force 

●

 Heavy 

steering 

●

  Reduction of handling stability 

●

  Sudden steering during the acceleration 

●

  Direction of torque control 

Tire rotation 

Front and rear tires have different functions and 
will lead to uneven wears, which is determined by 
road surfaces for driving and different driving 
habits,etc. The wear rate of front wheel tire is 
below that of rear wheel tire. 

In order to avoid uneven wears of tire and extend 
its service life, rotate the tire every 10,000km. 
After rotating the tire, adjust its air pressure, and 
ensure that the torque of hub nut meets the 
specified requirements. 

Minimum pattern depth 

1.6mm(0.06 inch) 

 

Wheel balance 

It’s a simple process to check the wheel balance. If 
the wheel jumps at high speed, it shall be first 
checked by you. During the replacement of wheels 
and tires, their balances must be checked. 

While checking the wheel balance, be sure to 
follow the rules below: 

①

  The number of balance blocks shall not 

exceed two on inner or outer side of one 
wheel; 

②

  The total weight of one wheel balance block 

shall not exceed 100g (3.5 ounce); 

Diagnostic data and procedures 

Tire wears 

①

  Check the depth of tire pattern. 

②

  If the depth of its pattern is below the given 

value, please replace the tire. 

 

It can be seen from the specifications that the tire 
must be replaced when the depth of tire pattern is 
reduced (below 1. 6mm (0. 06 inch)). 

 

 

Wheels and tires 2C-5 

 

 

Irregular or excessive wears of tire

 

Fault

 

Possible causes

 

Corrective measures

 

 

 

●

  Overlow tire pressure 

●

 Improper tire rotation

 

●

  Adjust the tire pressure. 

●

 Rotate the tire.

 

 

●

  Overhigh tire pressure 

●

 Improper tire rotation

 

●

  Adjust the tire pressure. 

●

 Rotate the tire.

 

 

●

 Improper toe-in

 

●

  Adjust the toe-in.

 

 

●

 Reverse toe-in

 

●

  Adjust the toe-in.

 

 

●

  Improper kingpin caster angle 

or improper front-wheel 
camber 

●

 Suspension failure 

●

  Improper wheel balance 

●

 Improper tire rotation

 

●

 Check the steering knuckle, 

control connecting rod, drive 
shaft and suspension. Replace 
if necessary. 

●

  Adjust the balance of wheel. 

●

 Rotate the tire.

 

 

 

Wheels and tires 2C-6 

 

Repair instructions 

(I) Vehicle 

repair 

 

 

 

 

 

 

 

Wheel 

I. 

Sequence of removal 

①

  Remove the steel wheel outer trim cover; 

②

  Remove the hub nut; 

③

  Lift the wheel stably. 

Note:  don’t loosen the tightened wheel by heating 
it. It will shorten the service life of wheel, hub nut 
and wheel bearing. Excessive force application, e.g. 

hitting the wheel or tire, will also cause the 
damages, which can’t be recovered. It’s allowed to 
hit the sides of wheel slightly with a hand or 
rubber hammer. 

④

 

Remove the wheel. 

If it’s difficult to remove the wheel from the 
vehicle, it may be caused by the existence of 
sundries or excessive close fit among the wheel 
middle holes, nuts and hubs. At this time, the 
wheel can be removed from the vehicle by 
adopting the following methods: 

A.  Re-tighten any influenced hub nut, and then 

turn the hub nut two circles in its loosening 
direction. 

B.  Lower the vehicle, try to shake the vehicle, 

and adopt the weight of one or several 
persons to loosen the wheel.  

C.  Lift up the vehicle again, and then remove the 

wheel. 

Note:  don’t apply the lubricating oil to vertical 
surface of wheel and hub (or brake disc), because 
the existence of lubricating oil in these positions 
will lead to the wheel loosening when the vehicle 
is driven, control failure of vehicle and even 
serious accidents. The lubricating oil is not good 
for removal of tightened wheel. If the lubricating 
oil is required, don’t apply too much oil, and only 
to the centerhole area of wheel. 

II.  Sequence of installation 

Note:  before installing the wheel, please remove 
the sundries from the mounting faces of wheel, 
brake drum and hub with a hairbrush. If the surface 
contact is poor during the installation, it will 
loosen the hub nut. While the vehicle is driving, 
there may be a risk of disengaging the wheel from 
the vehicle. The hub nut must be tightened as per 
the specified torque, but its tightening force shall 
not be excessive, thus the bends of wheel, brake 
drum or hub can be avoided. 

①

  Install the wheel. 

②

  Install the hub nuts in diagonal order. Don’t 

tighten the hub nut. 

③

  Lower the vehicle. 

④

 Tighten 

it. 

Tighten the hub nuts up to the torque of 100 to 120 
N.m (73.3 to 88.3 lb-ft). 

⑤

 Wheel 

balance 

Measure the balance of wheel with an automatic 
balancing machine. The balancing machine is 
convenient in operation, its static and dynamic 

 

Wheels and tires 2C-7 

 

balance can be also measured. Unlike the balance 
of vehicle, don’t calibrate the unbalance of vehicle, 
brake drum or hub. This defect can be resolved by 
precision. During the balancing work, make the 
taper part through the wheel center hole to fix the 
wheel, and don’t do so through the mounting hole 
of hub nut. 

⑥

  Calibrate the unbalanced tire. 

Provide two methods to calibrate the unbalanced 
tire. 

One method is to fix the tire through this automatic 
device, and then hit small yellow rubber blocks on 
both sides of tire tread. Such calibration method is 
usually permanent. 

If it’s well handled, it won’t influence its 
appearance or tire service life. 

It’s not recommended to calibrate any tire with a 
blade-shape machine, because it can reduce the 
service life of tire tread, and the tire can’t be 
permanently calibrated.  

The other method is to remove the tire, and then 
turn it by 180

ﹾ on the rim. The unbalance of wheel 

or tire must be known before doing so, because 
this method can ensure the balance of its assembly. 

⑦

 Installation of tire and wheel 

The tire and wheel shall be installed in the 
assembling workshop. During the installation, 
install them by aligning the radial hard point or 
heavy balancing point of tire to the radial dot or 
light balancing point of wheel. 

The heavy balancing point of tire is marked with a 
red dot during the start of its production, or marked 
on the tire side with a label. 

The light balancing point of wheel is located at the 
inflating valve. 

Before installing the tire and wheel, scribe a line 
on the tire and inflating valve to ensure that they 
can be installed in the same position during the re-
installation.  

The quality of spare tire and original tire shall be 
the same, and their heavy and light points shall be 
marked with the same method. 

Instructions 

Instructions for tire size and air pressure 

Inflation pressure 

 

Front Rear 

 

Tire Wheel 

kPa psi kPa psi 

185/60 R15 

15×5. 5J (steel) 

220 

32 

220 

32 

195/55 R15 

15×6J (aluminum) 

220 

32 

220 

32 

 

Instru`ctions for converting the inflation pressure

 

kPa psi 

kPa 

psi 

kPa  psi 

140 20 

186 

27 

234  34 

145 21 

193 

28 

241  35 

152 22 

200 

29 

248  36 

159 23 

207 

30 

276  40 

166 24 

214 

31 

310  45 

172 25 

220 

32 

345  50 

179 26 

228 

33 

379  55 

Instructions for tightening torque 

Type

 

N.m

 

Ib.Ft

 

Ib.In

 

Hub nut(aluminum alloy 

wheel)

 

100 to 120

 

66 to 81

 

－

 

Hub nut(steel wheel)

 

100 to 120

 

66 to 81

 

－

 

 

Suspension system 2D-2 

 

 

 

Suspension system 2D-1 

 

Chapter 13  Suspension system 

 

General procedures .................................................................................................................................2D-2 

Attentions for suspension system......................................................................................................2D-2 

Front suspension......................................................................................................................................2D-3 

Check of front shock absorber ..........................................................................................................2D-2 

Warning for scrapping the front shock absorber ...............................................................................2D-2 

Removal/installation of front suspension lower swing arm assembly ..............................................2D-3 

Removal/installation of front transverse stabilizer bar......................................................................2D-4 

Rear suspension .......................................................................................................................................2D-5 

Removal/installation of rear shock absorber and spring ...................................................................2D-5 

Notes for mounting rear spiral spring................................................................................................2D-6 

Removal/installation of torsion beam integral axle...........................................................................2D-6 

 

 

 

Suspension system 2D-2 

 

General procedures 

Attentions for suspension system 

Removal/installation of wheel and tire 

1.  Its tightening torque during the installation of 

wheel:100-120N.m {10. 0-12. 0kgf.m,77. 3-
88. 3in.lbf} 

Removal/installation of suspension tie rod 

1.  Each part of suspension with rubber bush can 

be tightened only after the vehicle is laid 
down and at empty load. 

Empty load: the fuel tank is full, the levels of 
cooling oil and lubricating oil in engine reach the 
specified liquid level, the spare tire jack and tool 
are placed in specified positions. 

Cutoff/connection of brake pipe 

Note:  the brake oil will damage the paint surface. 
If the brake oil contacts with the paint surface, 
remove it immediately. 

1.  Tighten the brake pipe taper nut with SST 

special service tool 490 259 770B, and 
confirm the adjustment of brake pipe taper nut 
tightening torque to ensure the combined use 
of torque wrench and SST special service tool. 

2.  If any brake pipe is disconnected in this 

process, add in the brake oil, remove the 
residual air out of brake system, and check it 
for leakage after terminating the operation. 

Removal/installation of power steering part 

1.  If any power steering oil line is disconnected 

in this process, add in DEXRON-III or ATF-
III oil, remove the residual air out of oil line, 
and check it for leakage after terminating the 
operation. 

Location of wheel 

Initial check of wheel location 

1.  Check the inflation of tire, and adjust its 

pressure to the recommended pressure as per 
the demands. 

2.  Check the front wheel bearing clearance, and 

apply the necessary calibrations to it as per 
the demands (refer to the check of M wheel 
bearing clearance). 

3.  Check the radial runout of wheel and tire 

(refer to TD suspension). 

4.  Check the ball joint and steering linkage for 

excessive loosening. 

5.  Shake the vehicle body to check the operation 

of shock absorber.  

Note:  the vehicle must be placed on horizontal 
road surface at empty load. 

Empty load: the fuel tank is full, the levels of 
engine cooling oil and lubricating oil reach the 
specified liquid level, the spare tire jack and tool 
are placed in specified positions. 

6.  Measure the vertical height from wheel center 

to wheel fender edge, and the difference 
between the values measured on left and right 
sides can’t exceed 10mm {0.39 in}. 

 

Location of front wheel Technical parameters (empty load)

*1 

 

Item 

Parameters 

mm {in}

0±2 

Total toe-in 

°

0°00’±0°12’ 

Inner side wheel 

37. 79° 

Maximum value of steering 
angle 

Outer side wheel

33. 36° 

kingpin caster angle(reference value) *2 

2°35'±30' 

front-wheel camber 

-0°30'±30' 

Kingpin inclination angle (reference value)*2 

13°20'±30' 

1. The levels of engine cooling oil and lubricating oil reach the specified liquid level, and the spare tire jack 
and tool are placed in specified positions.  

2. The difference between the values measured on left and right sides can’t exceed 1º30’. 

Measured point 

A-A section

 

Suspension system 2D-3 

 

Adjustment of maximum steering angle 

1.  Loosen the end lock nuts of steering linkage. 

2.  Remove the steering gear boot clamp. 

3.  Make the length of steering linkage equal to L. 

 

Maximum difference between left/right values of 
3mm {0.12 in} 

4.  Adjust the steering linkage evenly to ensure 

its corresponding maximum steering angle. 

5.  Tighten the end lock nut of steering linkage. 

Tightening torque: 66-86N.m {6.0-
8.6kgf.m,48.7-63. 4in.lbf} 

6.  Ensure that the gland cover is not twisted, and 

install the boot clamp. 

7.  Adjust the toe-in after adjusting the steering 

angle. 

Adjustment of total toe-in 

1.  Locate the steering wheel in middle position, 

and ensure that the wheel/tire is right ahead. 

2.  Loosen left and right steering linkage lock 

nuts, keep the rotations of both side linkages 
equal to each other, both side steering 
linkages are right hand threads, so right 
steering linkage shall be turned in front of 
vehicle, and left steering linkage shall be 
turned back to increase the toe-in. 

Note:  turn each of both steering linkages by a 
complete circle, and change the toe-in by about 
6mm {0.24 in} 0º36’. 

3.  Tighten the lock nut of steering linkage up to 

the specified tightening torque: 66-86N.m 

{6.0-8.6kgf.m, 48.7-63.4in.lbf} 

Location of rear wheel 

Technical parameters (empty load) 

Indications of fuel 

meter 

Empty--full 

Total toe-

out 

mm 3±3 

Rear wheel camber 

angle (reference value)

-1°00’±45’ 

 

Front suspension 

Removal/installation of front shock 
absorber and spring 

Note 

In case of not removing ABS anti-lock brake 
system wheel speed sensor first, carry out the 
following operation procedures. If the sensor is 
inadvertently pulled, it may cause the broken 
circuit of wire. Before carrying out the following 
operation procedures, remove ABS wheel speed 
sensor from axle side, and fix it in appropriate 
position to prevent the sensor from inadvertent 
pulling during the repair of vehicle. 

1.  Remove it in the sequence shown in the table; 

2.  Install it in the reverse sequence of removal; 

3.  Check the location of front wheel. In case of 

not conforming to the standard provisions, 
adjust the location of front wheel (refer to the 
location of R front wheel). 

Difference between left and right 
values is below 3mm(0. 12in) 

 

Suspension system 2D-4 

 

 

 

1 

Bolt and brake 
hose 

7 

Upper bracket 
of spiral spring 

2 

Fixing bolt and nut 
of shock absorber 
andsteering 
knuckle 

8 

Upper rubber 
mount 

3 

Fixing nut of shock 
absorber and 
vehicle body 

9 

With a stop 
block dust cover

4 

Piston rod nut 
Refer to the 
keypoints for 
removal of R-4 
piston rod nut. 

10 

Front spiral 
spring 

5 

Upper support of 
damping column 

11 

Lower rubber 
mount 

6 

Damping column 
bearing 

12 

Front shock 
absorber 
assembly 

Keypoints for removal of piston rod nut 

Warning: 

It’s dangerous to remove the piston rod nut, the 
shock absorber and spring may pop up due to huge 
pressure, thus it will lead to serious personal injury 

and death. Ensure that the shock absorber shall be 
installed inside SST special service tool before 
removing the piston rod nut. 

1.  Protect the spiral spring with a cloth, and then 

place SST special service tool. 

2.  Compress the spiral spring and remove the 

piston rod nut with SST special service tool. 

 

In case of applying the engine support 

 

 

Suspension system 2D-2 

 

Keypoints for installing the stop block 

Apply the grease to the contact surface of stop 
block and dust cover. 

Keypoints for installing the dust cover 

Apply the grease to the contact surface between 
the dust cover and upper spring retainer. 

Keypoints for installing the spiral spring 

1.  First install the upper spring rubber retainer 

and upper spring retainer on the shock 
absorber to make the lower end of helical 
spring placed on lower spring retainer. 

2.  As shown in the figure, make the marks on 

upper spring rubber retainer and upper spring 
retainer on spiral spring for the purpose of 
correct installation. 

 

3.  Align the marks on upper spring rubber 

retainer and upper spring retainer of spiral 
spring, protect the spiral spring and upper 
retainer spring with cloth, and then set SST 
special service tool. 

4.  Compress the spiral spring with SST special 

service tool. 

5.  Install the lower spring rubber retainer on 

lower spring retainer. 

6.  Install the shock absorber to make the lower 

end of spiral spring placed on lower spring 
retainer. 

7.  Ensure that the marks of shock absorber and 

upper spring retainer are aligned to each other. 

8.  As shown in the figure, install the bearing 

fixing rubber seat and piston rod nut, and then 
remove SST special service tool. 

 

Tightening torque of piston rod nut:80-90N.m{8-9 
kgf.m, 59-66. 4in.lbf}  

Keypoints for installing front shock absorber 
and spring 

The upper support of shock absorber has wrong-
installation-proofing functions, which ensure no 
wrong installation during the installation. 

Check of front shock absorber 

1.  Remove front shock absorber from the 

vehicle. 

2.  Check the shock absorber for damages or oil 

leakage. 

3.  Check the rubber bush for aging and wears. 

4.  Compress and stretch the shock absorber 

piston at least three times, confirm the 
unchanged operating force and no abnormal 
noises. If it can’t conform to the standards, 
replace the shock absorber. 

(1)  Compress the shock absorber piston, and then 

release it. 

(2)  Confirm that the piston stretches and returns 

at normal speed. 

 

Warning for scrapping the front shock 
absorber  

  Wear the safety goggles in case of each 

drilling of shock absorber, because the high-
pressure gas in the shock absorber may inject 
the metal shavings to the eyes and faces while 
drilling. 

1.  Clamp the shock absorber down on the plane 

by making the piston down. 

2.  Drill a hole φ2-3 mm {0.08-0.12 in} in the 

position 20-30mm {0.8-1.2 in} away from the 
pipe bottom to make the gas leaked out. 

Upper spring 

retainer 

Dent 

Exterior 

of vehicle 

Mark

 

Suspension system 2D-3 

 

 

3.  Make the hole down. 

4.  Collect the oil by moving up and down the 

piston rod several times and cutting the pipe 
ends. 

5.  Handle the waste oil as per the waste material 

processing regulations. 

Note:  the gas applied in the shock absorber is 
nitrogen, and the oil applied in the shock absorber 
is mineral oil. 

Removal/installation of front suspension 
lower swing arm assembly 

1.  Remove it in the sequence shown in the 

table. 

2.  Install it in the reverse sequence of 

removal. 

 

 

Keypoints for removing the dust cover 

Remove the dust cover with a chisel, and don’t 
damage the ball joint and arm lever. 

 

Keypoints for removing the lower swing arm 
front bush 

Press it down with SST special service tool, and 
remove the lower swing arm front bush. 

 

Keypoints for removing the lower swing arm 
rear bush 

1.  As shown in the figure, align to rear small 

bump of lower swing arm bush, and make the 
mark on lower swing arm for the purpose of 
correct installation.  

 

 

1 Self-lock 

nut 

2 Self-lock 

nut 

3 Hexagon 

flange 

bolt 

4 Hexagon 

flange 

bolt 

5 Hexagon 

flange 

bolt 

6 

Front suspension lower swing arm assembly 

7 

Swing arm front bush 

8 

Swing arm rear bush 

2.  Press it down with SST special service tool to 

remove the bush of lower swing arm. 

 

Keypoints for installing lower swing arm rear 
bush 

Hydraulic machine is 
pressed in by force 

Special tools 

Special tools 

Front bush 

Small bump

Mark

 

Press in