ZEST BOLT Service Manual

SUSPENSION CONTENTS 6.1 TECHNICAL SPECIFICATION AND TIGHTENING TORQUE. ................................................... 1 6.1.1 Specification.. ........................................................................................................................................1 6.1.2 Tightening Torque for Suspension.. ..................................................................................................... 2 6.2 SPECIAL TOOLS.. ....................................................................................................................... 3 6.3 DIAGNOSIS. ................................................................................................................................. 4 6.4 PRECAUTION. ............................................................................................................................. 5 6.5 SUSPENSION SYSTEM. ............................................................................................................. 6 6.6 ASSEMBLY FRONT SUSPENSION.. ........................................................................................ 10 A) Assembly Front Strut Exploded View.. ............................................................................................... 10 B) Anti Roll Bar Mounting Exploded View.. ..............................................................................................11 C) Lower Link Exploded View.. ............................................................................................................... 12 D) Front Axle Assembly Exploded View. ................................................................................................. 13 6.7 FRONT SUSPENSION. .............................................................................................................. 14 6.7.1 Removal and Installation of Strut Assembly.. ..................................................................................... 14 6.7.2 Disassembly and Assembly of Front Strut.. ....................................................................................... 15 6.7.3 Removal and Installation of Wheel Hub. ............................................................................................ 17 6.7.4 Removal and Installation of sub-frame assembly. .............................................................................. 20 6.7.4.1 Removal and Installation of Anti roll bar. ........................................................................................... 21 6.7.4.2 Removal and Installation of Ball Joint.. .............................................................................................. 22 6.7.4.3 Removal and Installation of Lower ARM Rubber Bushes.. ................................................................ 23 6.8 ASSEMBLY REAR SUSPENSION... ..........................................................................................25 A) Rear Shock Absorber and Spring Exploded View.. ............................................................................ 25 B) Assembly Rear Hub Exploded View.. ................................................................................................ 27 C) Pivot Mounting Bracket and Bush Exploded View.. ........................................................................... 28 6.9 REAR SUSPENSION ................................................................................................................ 29 6.9.1 Removal and Installation of Rear Shock Absorber and Coil Spring.. ................................................. 29 6.9.1.1 Removal of Rear Shock Absorber and Coil Spring.. .......................................................................... 29 6.9.1.2 Disassembly and Assembly of Rear Shock Absorber.. ...................................................................... 31 6.9.1.3 Installation of Rear Shock Absorber and Coil Spring.. ....................................................................... 32 6.9.2 Removal and Installation of Torsion Beam from Car... ....................................................................... 33 6.10 WHEELS AND TYRES.. ............................................................................................................. 38 A) Tyre Inspection.. ................................................................................................................................. 38 B) Replacement of Tyres. ....................................................................................................................... 38 C) Replacement of Wheel.. ..................................................................................................................... 38 6.10.1 How to Measure Wheel Run out.. ...................................................................................................... 38 6.10.2 Inflation of Tyre... ................................................................................................................................ 39