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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
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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
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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
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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
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NOTES