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============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 FORTE/FORTE KOUP(TD) > 2010 > G 2.0 DOHC > Suspension System Suspension System > General Information > Specifications Specifications Front Suspension Item Specification Suspension type MacPherson Strut Shock absorber Type Gas Coil spring Free Height [I.D color] 319.84mm (RED - 2) 326.74mm (GRAY - 2) Rear Suspension Item Specification Suspension type Torsion Beam Axle Shock absorber Type Gas Coil spring Free Height [I.D color] 288.63mm (GREEN) 272.73mm (BLUE/RED - 1) Wheel & Tire Item Specification 5.0J x 15 Wheel Aluminum 6.0J x 16 7.0J x 17 Steel 5.5J x 15 185/70 R15 195/65 R15 Tire 205/60 R16 215/50 R17 215/45 R17 Tire pressure 2.2kg/cm² (32psi) Wheel Alignment Specification Item 4DR/5DR 2DR Total 0.12°±0.18° 0.4°±0.2° Individual 0.06°±0.09° 0.2°±0.1° Camber -0.64°±0.5° -0.81°±0.5° Caster 4.38°±0.5° 4.94°±0.5° King-pin 13.61°±0.5° 14.01°±0.5° 0.4°±0.2° 0.4°±0.2° Toe-in Front Rear Toe-in Total 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 Individual 0.2°±0.1° -1.5°±0.5° Camber 0.2°±0.1° -1.5°±0.5 Tightening Torques Front Suspension Item Tightening torque (kgf.m) Nm Kgf.m lb-ft 90 ~ 110 ~ 11 65 ~ 80 140 ~ 160 /100 ~ 120 14 ~ 16 /10 ~ 12 101 ~ 115 /72 ~ 87 24 ~ 34 2.4 ~ 3.4 72 ~ 87 MDPS 50 ~ 65 ~ 6.5 36 ~ 47 HPS 60 ~ 80 6~8 43 ~ 58 100 ~ 120 10 ~ 12 72 ~ 87 45 ~ 55 4.5 ~ 5.5 32 ~ 40 Stabilizer bar to front strut assembly 100 ~ 120 10 ~ 12 72 ~ 87 Front strut assembly to front axle 140 ~ 160 14 ~ 16 101 ~ 115 Hub nuts Lower arm to sub frame Tie rod end castle nut Steering gear box to sub frame Stabilizer bar to stabilizer link Stabilizer bar to sub frame Rear Suspension Item Tightening torque (kgf.m) Nm Kgf.m lb-ft Hub nuts 90 ~ 110 9.0 ~ 11.0 65 ~ 80 Shock absorber to body 100 ~ 120 10.0 ~12.0 72 ~ 87 Shock absorber to torsion beam axle 100 ~ 120 10.0 ~12.0 72 ~ 87 Torsion beam axle to body 100 ~ 120 10.0 ~ 12.0 72 ~ 87 Suspension System > General Information > Special Service Tools Special Service Tools Tool (Number and Name) Illustration Use 09546-26000 Strut spring compressor Compression of coli spring 09568-2J100 Ball joint puller Remover of ball joint 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 09568-4A000 Ball joint puller Separation of tie-rod end ball joint Suspension System > General Information > Troubleshooting Troubleshooting Symptom Hard steering Possible cause Improper front wheel alignment Excessive turning resistance of lower arm ball joint Low tire pressure No power assist Poor return of steering Improper front wheel alignment wheel to center Poor or rough ride Remedy Correct Replace Adjust Repair and replace Correct Improper front wheel alignment Malfunctioning shock absorber Broken or worn stabilizer Broken or worn coil spring Worn lower arm bushing Correct Repair or replace Replace Replace Replace the lower arm assembly Abnormal tire wear Improper front wheel alignment Improper tire pressure Malfunctioning shock absorber Correct Adjust Replace Wandering Improper front wheel alignment Poor turning resistance of lower arm ball joint Loose or worn lower arm bushing Correct Repair Retighten or replace Vehicle pulls to one side Improper front wheel alignment Excessive turning resistance of lower arm ball joint Broken or worn coil spring Bent lower arm Correct Replace Replace Repair Steering wheel shimmy Improper front wheel alignment Poor turning resistance of lower arm ball joint Broken or worn stabilizer Worn lower arm bushing Malfunctioning shock absorber Broken or worn coil spring Correct Replace Replace Replace Replace Replace Bottoming Replace Replace Broken or worn coil spring Malfunctioning shock absorber Wheel /tire noise, vibration and harshness concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating Also, out-of-balance wheel and tires can vibrate at more than one speed A vibration that is affected by the engine rpm, or is eliminated by placing the transmission in Neutral is not related to the tire and wheel As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies This can initially isolate a concern to the front or rear Careful attention must be paid to the tire and wheels There are several symptoms that can be caused by damaged or 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 worn tire and wheels Perform a careful visual inspection of the tires and wheel assemblies Spin the tires slowly and watch for signs of lateral or radial runout Refer to the tire wear chart to determine the tire wear conditions and actions Wheel and tire diagnosis Rapid wear at the center • Center-tread down to fabric due to excessive over inflated tires • Lack of rotation • Excessive toe on drive wheels • Heavy acceleration on drive Rapid wear at both shoulders • Under-inflated tires • Worn suspension components • Excessive cornering speeds • Lack of rotation Wear at one shoulder • Toe adjustment out of specification • Camber out of specification • Damaged strut • Damaged lower arm Partial wear Feathered edge Wear pattern • Caused by irregular burrs on brake drums • Toe adjustment out of specification • Damaged or worn tie rods • Damaged knuckle • Excessive toe on non-drive wheels • Lack of rotation Suspension System > Front Suspension System > Components and Components Location Components 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 Sub frame Strut Assembly Lower Arm Drive Shaft Stabilizer Bar Suspension System > Front Suspension System > Front Strut Assembly > Components and Components Location Components 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 Nuts Lock nut Insulator Strut bearing Spring upper pad Strut dust cover & bumper rubber Coil spring Spring lower pad Piston road 10 Strut assembly 11 Spring lower seat Suspension System > Front Suspension System > Front Strut Assembly > Repair procedures Replacement Remove the front wheel & tire Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 110 (9.0 ~ 11.0, 65 ~ 80) Remove the brake hose and the wheel speed sensor bracket from the front strut assembly by loosening the mounting bolts 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 Disconnect the stabilizer link with the front strut assembly after loosening the nut Tightening torque Nm (kgf.m, lb-ft) : 100 ~ 120 (10.0 ~ 12.0, 72 ~ 87) Remove the cap and than loosen the strut mounting nuts Disconnect the front strut assembly with the knuckle by loosening the bolt & nut Tightening torque Nm (kgf.m, lb-ft) : 140 ~ 160 (14.0 ~ 16.0, 101 ~ 115) 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 Installation is the reverse of removal Disassembly Using the special tool (09546-26000), compress the coil spring (A) until there is only a little tension of the spring on the strut Remove the self-locking nut (C) from the strut assembly (B) Remove the insulator, spring seat, coil spring and dust cover from the strut assembly Inspection Check the strut insulator bearing for wear or damage Check rubber parts for damage or deterioration Compress and extend the piston rod (A) and check that there is no abnormal resistance or unusual sound during operation 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 Reassembly Install the spring lower pad (D) so that the protrusions (A) fit in the holes (C) in the spring lower seat (B) Compress coil spring using special tool (09546-26000) Install compressed coil spring into shock absorber 1) Indicated two identification color marks on the coil spring one follows model option (see page SS-2) the other follows load classification according to the below Pay attention to distiuguish between the two marks and then install them 2) Install the coil spring wth the idemtification mark directed toward the knuckle After fully extending the piston rod, install the spring upper seat and insulator assembly After seating the upper and lower ends of the coil spring (A) in the upper and lower spring seat grooves (B) correctly, tighten new self-locking nut temporarily Remove the special tool (09546-26000) Tighten the self-locking nut to the specified torque Tightening torque : 50 ~ 70 Nm (5 ~7 kgf·m, 36 ~ 50 lb-ft) Suspension System > Front Suspension System > Front Lower Arm > Repair procedures Replacement Remove the front wheelballtire mounting bolts Remove the lower arm & joint Tightening torque Nm (kgf.m, lb-ft) : Tightening torque Nm (kgf.m, lb-ft) : 90 ~~ 120 (10.0 11.0, 6572 80) 100 110 (9.0 ~ ~ 12.0, ~ ~ 87) 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 10 of 43 Remove the lower arm mounting bolts Tightening torque Nm (kgf.m, lb-ft) : 100 ~ 120 (10.0 ~ 12.0, 72 ~ 87) Tightening torque Nm (kgf.m, lb-ft) : 140 ~ 160 (14.0 ~ 16.0, 101 ~ 115) Using the special tools (09214-32000 & 09216-211000), remove the bushing from the lower arm 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 29 of 43 Select the model and per from the sensor registration procedure accroding to instruction of the GDS 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 30 of 43 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 31 of 43 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 32 of 43 Vin And Vehicle Name Writing Install GDS (Global Diagnostic System) and GDS TPMS module to vehicle Select the model and perform the VIN and vehicle name writing procedure according to instruction of the GDS as follows [VIN Writing] 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 33 of 43 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 34 of 43 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 35 of 43 Suspension System > Tire Pressure Monitoring System > TPMS Sensor > Repair procedures Removal Removing The Tire From The Rim 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 36 of 43 During all the operations on the tire, the sensor must be correctly maintained and thus it is FORBIDDEN to unscrew the nut and to force the sensor into the wheel This could damage the sensor Take off the first side of the tire The tool should not be used near the valve (no less than 30 cm) Take off the second side of the tire The tool should not be used near the valve (No less than 30 cm) Dismount the first side of the tire: Place the shoe of the tool between and 15 cm away from the sensor and use the tire lever as shown in the picture By using the tire lever, extract the external side wall of the tire and engage on the shoe of the machine The lever and the tire must not come into contact with the sensor Then remove the lever 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 37 of 43 The wheel rotation allows the complete extraction of the first side of tire Raise the tire to prepare the introduction of the tire lever to aid extraction of the second side wall, the same recommendations as for the first side wall will apply By using the tire lever, extract the external side wall of the tire and engage the shoe of the machine The lever and the tire must not come into contact with the sensor Then remove the lever Extract entirely the second side wall of the tire 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 38 of 43 Pressure Sensor Removing While supporting the sensor unit, unscrew the nut Remove the sensor Installation Sensor Reinstallation Hold the sensor and the seal washer, then extract it, this also extracts the seal Take care to not damage the valve thread 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 39 of 43 Clean the sensor and the valve stem holding the valve using a dry cloth as shown on the picture Take care to support the rear of the valve with a thumb so that there is no movement of the stem When removing the sensor, a new washer and seal must be used Insert these up to the base of the sensor, making sure to secure the valve base with a thumb, as shown Wipe the seal and threading Insert the valve, in the valve hole, without modifying the angle of the stem (retain position of delivery) The laser marking should be visible to the operator 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 40 of 43 When the valve is completely inserted, maintain the sensor in contact with the rim (as shown on the picture), then screw manually the nut until it is in contact with the wheel (without force) While maintaining the sensor contact with the rim by applying pressure to the back of the valve, slightly press on the cap towards the center of the wheel in order to adapt the angle of the valve/sensor to the profile of the rim It is mandatory to guarantee the contact of the housing unit on the rim drop center While maintaining the sensor unit and valve in position, screw the nut with a torque wrench Apply a torque of 7.5 ~ 8.5Nm (0.76 ~ 0.86kgf.m, 5.5 ~ 6.2lb-ft) Take care that the wrench socket is correctly inserted on the nut Check the followings (1) It is normal that the seal washer becomes bent during the nut tightening (2) Check that the visible part of the antenna is not damaged or broken (3) The plastic bridge should neither be cracked nor broken It is designed so that it will fracture due to an error in the assembly process (too high torque, bad positioning……) Any defect must mean the rejection of the sensor Mounting of Tire 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 41 of 43 • Before any tire mounting operation, make sure that the sensor has been correctly mounted and tightened to the rim • No lubricant product or any other material may partially or completely cover the air pressure inlet hole of the sensor • The assembly tools have to never have a collision with the sensor • The tire cannot be in contact with the sensor only after it is engaged in the rim and after the exceeded peak of traction Therefore, generally at the end of the assembly Prepare the tire and fix the rim as usual Put the tire on the rim, so that the cross point of the belt with the rim is between 15 and 20 cm away from the valve (see the picture) Engage the shoe and make sure that 20cm is maintained between the cross point and the valve The arrow shows the direction of rotation of the wheel Turn the wheel in order to engage all the first side of the tire The standard shoes can pass over the sensor without damaging it 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 42 of 43 Put the second side of the tire in position, so that the cross point of the belt with the rim is approximately 20 cm away from the valve (see the picture) The curved arrow shows the direction of rotation of the wheel Turn the wheel in order to engage all of the second side of the tire The standard shoes can pass over the sensor without damaging it Perform the Register Sensor procedure (Refer to Register Sensor.) Suspension System > Tire Pressure Monitoring System > TPMS Receiver > Repair procedures Replacement Disconnect the battery negative cable from the battery Remove faulty part and fit bracket assembly to new part 9/16/2011 9:08 PM ============================================================================================================================ http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge 43 of 43 Secure new part to vehicle and fit connector Re-connect battery and turn ignition on Check that DTC flash rate matches virgin state indication 9/16/2011 9:08 PM ... rods • Damaged knuckle • Excessive toe on non-drive wheels • Lack of rotation Suspension System > Front Suspension System > Components and Components Location Components 9/16/2011 9:08 PM ============================================================================================================================... http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge of 43 Sub frame Strut Assembly Lower Arm Drive Shaft Stabilizer Bar Suspension System > Front Suspension System > Front Strut Assembly > Components and Components Location Components... Coil spring Spring lower pad Piston road 10 Strut assembly 11 Spring lower seat Suspension System > Front Suspension System > Front Strut Assembly > Repair procedures Replacement Remove the front