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SECTION 2C

FRONT SUSPENSION
TABLE OF CONTENTS
Description and Operation . . . . . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Strut Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Joint and Knuckle . . . . . . . . . . . . . . . . . . . . . Front Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . 2C-2 2C-2 2C-3 2C-3 2C-5 2C-5 2C-5 2C-6 Front Longitudinal Frame and Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10 Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-12 Strut Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-12 Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-13 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Bearing and Knuckle . . . . . . . . . . . . . . . . . Front Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . Special Tools and Equipment . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 2C-16 2C-16 2C-20 2C-23 2C-23 2C-23 2C-24 2C-24

Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2C-8

DAEWOO M-150 BL2

2C ญ 2 FRONT SUSPENSION

DESCRIPTION AND OPERATION
FRONT SUSPENSION
The front suspension for this vehicle is a combination knuckle/strut and spring design. The control arms pivot from the body. The lower control arm pivots use rubber bushing. The upper end of the strut is isolated by a rubber mount and contains a bearing to allow the wheel to turn. The lower end of the steering knuckle pivots on a ball joint bolted to the control arm. The ball joint is fastened to the steering knuckle with a bolt. When servicing the control arm-to-body attachment and the stabilizer shaft-to-body insulators, make sure the attaching bolts are loose until the control arms are moved to the trim height, which is curb height. Trim height is the normal position to which the control arms move when the vehicle is sitting on the ground. Refer to "General Specifications" in this section.

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 3

COMPONENT LOCATOR
FRONT SUSPENSION

D16B401A

DAEWOO M-150 BL2

2C ญ 4 FRONT SUSPENSION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Strut Bar Front Suspension Strut Assembly Strut Inner Support Strut Mount Assembly Strut Mount Seat Strut Bearing Seat Strut Bearing Coil Spring Upper Seat Coil Spring Seat Bumper Stopper Coil Spring Strut Inner Bearing Oil Seal Inner Hub Bearing Steering Knuckle Dust Cover Hub Bearing Spacer Outer Hub Bearing 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Outer Bearing Oil Seal Rotor Wheel Hub Hub Bolt Hub Assembly Drive AxleญtoญHub Caulking Nut Control Arm Ball Stud Bolt Cotter Pin Castellated Nut Washer Stabilizer Shaft Bushing Control Arm Dust Seal Clip Control Arm Bushing Control Arm Assembly Stabilizer Shaft Stabilizer Shaft Mount Front Under Longitudinal Frame

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 5

DIAGNOSTIC INFORMATION AND PROCEDURES
STRUT DAMPENER
A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand than are shock absorbers. Strut dampeners are used only on the front in most vehicles, including this vehicle. Shock absorbers are used on the rear wheels.

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Condition Probable cause Correction Struts Seem Weak D Improper tire pressures. D Adjust the tire pressures to the specifications on the tire placard. D Abnormal load conditions. D Consult with the owner to confirm the owner's understanding of normal load conditions. D Quickly push down and then lift up on the corner of the bumper nearest the strut dampener being tested. D Compare the compression and rebound with those of a similar vehicle that has an acceptable ride quality. D Replace the strut dampener, if needed. D Tighten the strut dampener. D Replace the strut dampener if needed. D Quickly push down and then lift up on the corner of the bumper nearest the strut dampener being tested. D Compare the compression and rebound with those of a similar vehicle that has an acceptable ride quality. D Replace the strut dampener, if needed. D The strut dampener is OK. D Replace the strut dampener. D Replace the strut dampener. D Improper compression and rebound effectiveness of the strut dampener. Struts are Noisy D Loose or damaged mountings. D Improper compression and rebound effectiveness of the strut dampener. Leaks D A slight trace of fluid. D Leaks of the seal cover on the fully extended strut. D Excessive leaks of fluid on the strut dampener.

BALL JOINT AND KNUCKLE
Ball Joint Inspection
1. Raise the front of the vehicle to allow the front suspension to hang free. 2. Grasp the tire at the top and the bottom. 3. Move the top of the tire in an in-and-out motion. 4. Look for any horizontal movement of the knuckle relative to the control arm. 5. Control arms assembly must be replaced if the following conditions exist: D The joint is loose. D The ball seal is cut. D The ball stud is disconnected from the knuckle.
DAEWOO M-150 BL2

D The ball stud is loose at the knuckle. D The ball stud can be twisted in its socket with finger pressure.

Ball Stud Inspection
Make sure to check the tightness of the ball stud in the knuckle boss during each inspection of the ball joint. One way to inspect the ball stud for wear is to shake the wheel and feel for movement of the stud end or the castellated nut at the knuckle boss. Another way to inspect the ball stud for wear is to check the fastener torque at the castellated nut. A loose nut can indicate a stressed stud or a hole in the knuckle boss. Worn or damaged ball joints and knuckles must be replaced.

2C ญ 6 FRONT SUSPENSION

FRONT WHEEL BEARING
Bearing Axial End Play Inspection

4. Check the standard torque of the drive nut (spec. : 210 NSm (155 lb-ft)). 5. Check the bearing end play according to the following method. D Place a dial guage against the disc surface, grasp the disc. D Using a pushญpull movement, note gage readings. 0.130mm or less (0.005 in) Standard tighting torque of drive shaft nut : 210 NSm (155 lb-ft)

Specification

D107B303

6. If the axial end play of the front wheel bearing exceed 0.130mm torque the drive shaft nut successively (Max. allowance : 240 NSm (177 lb-ft)) 7. Check the axial end play again. 8. If the axial end play is above spec., replace the front wheel bearing.

1. Lift and suitably support the vehicle. 2. Inspect the end play of the bearing. 3. If excessive play is defeeted, free shoes from the disc or remove the calipers.

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 7

REPAIR INSTRUCTIONS ONญVEHICLE SERVICE
STRUT ASSEMBLY
Removal Procedure
1. Open the hood. 2. Remove the top of the strut assembly at passenger seat side. D For vehicle with power steering, remove the power steering fluid reservoir (1). D Remove the nuts (2).

D16B501A

3. Remove the top of the strut assembly at driver side. D Remove the bolt and the fuse box (1, 2). D Remove the nuts (3).

D16B502A

4. Remove the lower of the strut assembly. D Raise and suitably support the vehicle. D Remove the wheel. Refer to Section 2E, Tires and Wheels. D Remove the ABS front speed sensor electrical wire from the bracket, if applicable (1). D Disconnect the brake hose from the bracket (2). D Remove the strut bracket bolts (3). 5. Remove the strut bracket assembly from the vehicle.

D106B503

DAEWOO M-150 BL2

2C ญ 8 FRONT SUSPENSION Installation Procedure
70ญ90 NSm 1. Install the strut assembly to the vehicle with the strut assemblyญtoญstrut bracket bolts.

Tighten
Tighten the strut assemblyญtoญstrut bracket bolts to 70ญ90 NSm (52ญ66 lb-ft). 2. Connect the brake hose to the bracket. 3. Install the ABS front speed sensor electrical wire to the bracket, if applicable.

D16B504A

18ญ28 NSm

4. Install the wheel. Refer to Section 2E, Tires and Wheels. 5. Lower the vehicle. 6. Install the nuts. D Install the nuts at passenger side (1).

Tighten
Tighten the nuts to 18ญ28 NSm (13ญ21 lb-ft). D Install the nuts at driver side (2).

Tighten
18ญ28 NSm
D16B505A

Tighten the nuts to 18ญ28 NSm (13ญ21 lb-ft). 7. Install the power steering fluid reservoir. 8. Install the fuse box and bolt.

KNUCKLE ASSEMBLY
Tools Required
KM 507ญB Ball Joint Remover

Removal Procedure
1. Remove the caulking nut. D Straighten the bent flange caulking nut (1). D Remove the caulking nut (2). D Remove the washer (3). 2. Remove the wheel. Refer to Section 2E, Tires and Wheels.
D106B506

3. Separate the tie rod end from the knuckle assembly. D Remove the cotter pin (1). D Remove the castellated nut (2). D Install the ball joint remover KM 507ญB. D Separate the tie rod end from the knuckle assembly using a ball joint remover KM 507ญB (3).

D105B501

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 9
4. Remove the control arm from the knuckle assembly. D Remove the stud bolt (1). D Separate the control arm from the knuckle assembly (2).

D106B507

5. Remove the brake caliper from the knuckle assembly. Refer to Section 4D, Front Disc Brakes. 6. Remove the ABS wheel speed sensor from the knuckle assembly, if applicable. Refer to Section 4F, Antiญlock Brake System. 7. Remove the steering knuckle assembly from the vehicle. D Remove the strut bracket bolts (1). D Separate the knuckle assembly from the drive shaft by pulling the steering knuckle assembly (2).

D106B508

Installation Procedure
70ญ90 NSm 1. Install in the reverse order of removal. 2. Install the steering knuckle assembly in the vehicle with strut bracket bolts (1).

Tighten
Tighten the strut bracket bolts to 70ญ90 NSm (52ญ66 lb-ft). 3. Install the brake caliper from the knuckle assembly. 4. Install the control arm into the knuckle assembly with the stud bolt (2). 50ญ70 NSm
D16B509A

Tighten
Tighten the stud bolt to 50ญ70 NSm (36ญ52 lb-ft). 5. Install the tie rod end to the knuckle assembly. 6. Install the tie rod endญtoญknuckle castellated nut (1) and the cotter pin.

Tighten
Tighten the castellated nut to 30ญ55 NSm (22ญ41 lbft). 7. Install the caulking nut (2). D Bend the caulking nut flange (3).

Tighten
Tighten the caulking nut to 210 NSm (155 lb-ft).
D16B510B

DAEWOO M-150 BL2

2C ญ 10 FRONT SUSPENSION

FRONT LONGITUDINAL FRAME AND STABILIZER SHAFT
Removal Procedure
1. Removed the front under longitudinal frame. D Raise and suitably support the vehicle. D Remove the front wheel. Refer to Section 2E, Tires and Wheels. D Remove the transaxle under cover. Refer to Section 5B, Manual Transaxle. D Remove the front under longitudinal frame bolt (1). D Remove the front under longitudinal frame nut (2). D Remove the stabilizer shaft mounting bolts (3). D Remove the front under longitudinal frame.

D106B511

D16B512A

2. Remove the stabilizer shaft from the vehicle. D Remove the cotter pin (1). D Remove the castellated nut (2). D Remove the washer (3). D Remove the rear bushing with separating the stabilizer shaft from the control arm (4).

D106B513

D Remove the bushing (5). D Remove the wire clamps (6). D Remove the mountings (7).

D16B514A

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 11 Installation Procedure
1. Install in the reverse order of removal. Important: When installing the mountings, position the opened mountings forward.

D16B515A

2. Install the stabilizer shaft to the vehicle. D Install the castellated nut.

Tighten
Tighten the stabilizer shaftญtoญbody castellated nut to 40ญ50 NSm (30ญ36 lb-ft). D Install the cotter pin.

40ญ50 NSm
D16B516A

3. Install the front under longitudinal frame. D Install the stabilizer shaft mounting bolts (1).

Tighten
Tighten the mounting bolts to 30ญ50 NSm (22ญ36 lbft).

D16B517C

D Install the front under longitudinal frame bolt (2).

Tighten
65 ญ 80 NSm Tighten to bolt to 10ญ14 NSm (89ญ124 lb-in). D Install the front under longitudinal frame nut (3).

Tighten
Tighten to nut to 65ญ80 NSm (48ญ59 lb-ft).

10 ญ 14 NSm
D16B518B

DAEWOO M-150 BL2

2C ญ 12 FRONT SUSPENSION

CONTROL ARM
Removal Procedure
1. Remove the stabilizer shaft. Refer to "Front Longitudinal Frame and Stabilizer Shaft" in this section. 2. Remove the control arm. D Remove the stud bolt (1). D Separate the control arm from the knuckle assembly using a lever (2).

D106B519

D Remove the bolt (3). D Remove the control arm.

D106B520

Installation Procedure
1. Install the control arm onto the vehicle. D Install the control arm bolt (1).

Tighten
Tighten the control arm bolt to 55ญ70 NSm (41ญ52 lbft). D Install the control arm to the knuckle assembly. D Install the stud bolt (2).

Tighten
D16B521B

Tighten the stud bolt to 50ญ70 NSm (36ญ52 lb-ft). 2. Install the stabilizer shaft.

STRUT BAR
Removal Procedure
1. Open the hood. 2. Remove the strut bar from the vehicle. D Remove the purge control valve (1). D Remove the A/C low pressure pipe bracketญtoญ strut bar nut (2). D Remove the strut bar bolts at passenger side (3).

D10B522A

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 13
D Remove the strut bar bolts at driver side (4). Important: When removing the bolts using the tool, do not contact the battery terminal. D Remove the strut bar at passenger side

D106B523

Installation Procedure
1. Install the strut bar to the vehicle. D Install the strut bar at passenger side. D Install the strut bar bolts at driver side (1). Important: When installing the bolts using the tool, do not contact the battery terminal. D Install the strut bar bolts at passenger side (2). D Install the A/C low pressure pipe bracketญtoญstrut bar nut.

Tighten
D16B524B

Tighten the strut bar bolts to 35ญ55 NSm (25ญ41 lb-ft). D Install the purge control valve to the strut bar.

CROSSMEMBER
Removal Procedure
1. Remove the transaxle under cover. Refer to Section 5B, FiveญSpeed Manual Transaxle. 2. Remove the front under longitudinal frame. Refer to "Stabilizer Shaft" in this section. 3. Remove the damping bush bolt and nut.

D106B525

4. Disconnect the power steering pressure line from the crossmember. Refer to Section 6B, Power Steering Pump. 5. Remove the crossmember from the vehicle. D Place support jack under the crossmember. D Remove the bumper fascia screws. D Remove the rear bolts (1). D Remove the side bolts (2). D Lower the support jack and remove the crossmember from the vehicle.
D106B526

DAEWOO M-150 BL2

2C ญ 14 FRONT SUSPENSION

D106B527

6. Remove the front damping bush bolts and damping bush from the crossmember.

D106B528

Installation Procedure
35ญ41 NSm 1. Install in the reverse order of removal. 2. Install the front damping bush to the crossmember.

Tighten
D Tighten the bolts to 45ญ55 NSm (33ญ41 lb-ft). a. Front damping bush bolt. D Tighten the bolt to 35ญ41 NSm (25ญ30 lb-ft). b. Front damping bush bolt.

45ญ55 NSm

D16B529A

3. Install the crossmember to the vehicle with the bolts.

Tighten
Tighten the bolts to 17ญ27 NSm (13ญ20 lb-ft). a. Crossmember right rear bolt. b. Crossmember right side bolt.

17ญ27 NSm

17ญ27 NSm
D16B530A

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 15
c. Crossmember left rear bolt. d. Crossmember leftt side bolt.

17ญ27 NSm

17ญ27 NSm
D16B531A

4. Install the front damping bush to the vehicle. 68ญ83 NSm

Tighten
Tighten the front damping bush bolt and nut to 68ญ83 NSm (51ญ61 lb-ft). 5. Install the front under longitudinal frame. Refer to "Stabilizer Shaft" in this section.

D16B532A

DAEWOO M-150 BL2

2C ญ 16 FRONT SUSPENSION

UNIT REPAIR
HUB BEARING AND KNUCKLE
Tools Required
DW 220ญ020Aญ01 DW 220ญ020Aญ04 DW 340ญ010 DW 340ญ020 DW 340ญ030 09940ญ71430 Differential Bearing Puller. Differential Bearing Plate Adapter. Front Wheel Hub Remover. Front Wheel Bearing Race Installer. Front Wheel Bearing Installer. Front Spring Compressor.

Disassembly Procedure
1. Remove the steering knuckle assembly. Refer to "Knuckle Assembly" in this section. 2. Remove the bolts from the wheel hub. 3. Remove the wheel hub from the knuckle assembly using the front wheel hub remover DW 340ญ010. D Remove the wheel hub using the front wheel hub remover DW 340ญ010 (1). D Remove the bearing spacer (2). D Remove the brake rotor (3).

D106B701

D106B702

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 17
D Remove the wheel bearing from the wheel hub using the differential bearing puller DW 220ญ020Aญ01 and differential bearing plate adapter DW 220ญ 020Aญ04 (4).

D16B703A

D Remove the oil seal from the wheel hub (5). Important: Do not use removed oil seal.

D106B704

4. Remove the steering knuckle assembly. D Remove the oil seal (1). Important: Do not use removed oil seal. D Remove the wheel bearing (2).

D106B705

D Remove the outer bearing race (3).

D106B706

DAEWOO M-150 BL2

2C ญ 18 FRONT SUSPENSION
D Remove the inner bearing race (4).

D106B707

Assembly Procedure
1. Assemble the steering knuckle assembly. D Assemble the inner bearing race using the front wheel hub remover DW 340ญ010 and the front bearing race installer DW 340ญ020 (1).

D106B708

D Assemble the outer bearing race using the front wheel hub remover DW 340ญ010 and the front wheel bearing race installer DW 340ญ020 (2).

D106B709

D Assemble the outer wheel bearing (3). D Assemble the outer wheel bearing oil seal (4).

D106B710

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 19
2. Install the wheel hub to steering knuckle assembly. D Install the brake rotor (1). D Install the wheel hub to the steering knuckle assembly temporary (2). D Press the outer wheel bearing into the wheel hub using the front wheel hub remover DW 340ญ010 and the front wheel bearing installer DW 340ญ030 (3).

D106B711

D Tighten the bolts (4).

Tighten
Tighten the bolt to 65 NSm (48 lb-ft).

D16B712A

D Install the bearing spacer (5).

D106B713

D Press the inner wheel bearing into the wheel hub using the front wheel hub remover DW 340ญ010 and the front wheel bearing installer DW 340ญ030 (6).

D106B714

DAEWOO M-150 BL2

2C ญ 20 FRONT SUSPENSION
D Install the inner wheel bearing oil seal (7). 3. Install the steering knuckle assembly. Refer to "Knuckle Assembly" in this section.

D106B715

FRONT STRUT (INCLUDING COIL SPRING)
Tools Required
09940ญ71430 Front Spring Compressor.

Disassembly Procedure
1. Remove the strut assembly. Refer to "Strut Assembly" in this section. 2. Compress the front spring with the front spring compressor 09940ญ71430. Caution: During compressing spring, do not make spring end point to operator or dangerous direction. 3. Fix the strut support using the bench vise and remove the strut nut. a. Strut nut.

D106B716

D106B717

DAEWOO M-150 BL2

FRONT SUSPENSION 2C ญ 21
4. Remove the coil spring. D Remove the strut inner support (1). D Remove the strut mount assembly (2). D Remove the strut mount seat (3). D D D D Remove the strut bearing seat (4). Remove the strut bearing (5). Remove the coil spring upper seat (6). Remove the coil spring seat (7).

D Remove the bumper stopper (8).

D16B718A

Assembly Procedure
50ญ60 NSm 1. Install the coil spring, front bumper stopper, coil spring seat, coil spring upper seat, strut bearing, bearing seat, mounting seat, mount assembly and inner support to the strut. 2. Tighten the strut nut. D Fix the strut support using the bench vise. D Tighten the nut.

Tighten
Tighten the strut nut to 50ญ60 NSm (36ญ44 lb-ft).
D16B719A

DAEWOO M-150 BL2

2C ญ 22 FRONT SUSPENSION
3. Inspect the installation of coil spring (1, 2). 4. Install the strut assembly. Refer to "Strut Assembly" in this section.

D106B720

DAEWOO M-150 BL2

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Wheel HubญtoญBrake Disc Bolt ABS Front Speed Sensor Retaining Bolt Strut Bar Bolts Crossmember Bolt Drive AxleญtoญHub Caulking Nut Front Under Longitudinal Frame Nut Front Under Longitudinal Frame Bolts Stabilizer Shaft Mounting Bolt Stabilizer Shaft Castellated Nut Control Arm Ball Stud Bolt Control Arm Mounting Bolt Strut AssemblyญtoญKnuckle Bolts Strut Closure Nut Strut AssemblyญtoญBody Nuts Grease Type (Front Wheel Bearing and Hub) Coil Spring Height (No Load) Stabilizer Shaft Diammeter Shock Absorber Suspension Type Application Application Stroke Minimum Length Maximum Length

DAEWOO M-150 BL2

FASTENER TIGHTENING SPECIFICATIONS

GENERAL SPECIFICATIONS

SPECIFICATIONS

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

Unit





55 ญ 75 18 ญ 28 35 ญ 55 17 ญ 27 65 ญ 80 10 ญ 14 30 ญ 50 40 ญ 50 50 ญ 70 55 ญ 70 70 ญ 90 50 ญ 60 18 ญ 28 NSm 210

FRONT SUSPENSION 2C ญ 23

Mญ8143 ANTIF BRG GREASE

321ญ327 (12.64ญ12.87)

475ญ481 (18.7ญ18.94)

41 ญ 55 13 ญ 21 25 ญ 41 13 ญ 20 48 ญ 59 22 ญ 36 30 ญ 36 36 ญ 52 41 ญ 52 52 ญ 66 36 ญ 44 13 ญ 21 Lb-Ft 155 ญ

Mcpherson (Strut)

Description

374 (14.72 )

154 (6.06)

24 (0.94)

89 ญ 124

Lb-In

ญ ญ ญ ญ ญ ญ ญ ญ ญ ญ ญ ญ ญ

2C ญ 24 FRONT SUSPENSION

SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE

DW 220ญ020Aญ01 Differential Bearing Puller

DW 340ญ030 Front Wheel Bearing Installer

D13B112A

D106B103

DW 220ญ020Aญ04 Differential Bearing Plate Adapter

KM 507ญB Ball Joint Remover

D13B113A

D105B101

DW 340ญ010 Front Wheel Hub Remover

09940ญ71430 Front Spring Compressor

D16B101A

D106B104

DW 340ญ020 Front Wheel Bearing Race Installer

D106B102

DAEWOO M-150 BL2