Removing
1. Raise and secure the vehicle.
2. Remove the front wheel from the vehicle.
3. Disconnect the tie rod end from the steering knuckle.
4. Unscrew the outer mounting of the lower suspension arm.
5. Remove the front brake disc.
6. Disconnect the drive shaft from the wheel hub with bearing.
7. Remove the front wheel speed sensor.
8. Disconnect the fork from the suspension strut.
9. Remove wheel hub with bearing.
10. Unscrew the kingpin bolt (1).
11. Clamp the suspension fork in a vice with soft jaws.
12. Install the puller CH-49859-1 (1) on the king pin (2) and hand-tighten the hexagon bolt (3) size six.
13. Remove the kingpin (2) with rotary knuckle (1).
14. Remove the puller CH-49859-1 (3) from the king pin.
15. Disconnect the upper ball joint of the steering knuckle (1) using pullers CH-50094 (2) and DT-161-B (3).
16. Loosen nuts (1) kingpin bushings so that they protrude two or three turns of thread above the bolts.
17. With hydraulic press (2) and fixtures CH-50093 (3), press out the bolts of the kingpin bush to the stop approximately 5 mm.
18. Completely unscrew the nuts (2) kingpin bushings and remove the bushing (1) from a fork (3), placing the drift on the sleeve and detaching it with hammer blows.
19. Loosen the nuts (2) and bolts (1) securing the upper ball joint of the steering knuckle.
20. Disconnect the upper ball joint (3) from the front suspension fork.
Installation
1. Insert holder CH-49859-2 (1) in bracket CH-49859-3 (2).
2. Insert and place the steering knuckle (4) exactly on fixture CH-49859 (3).
3. Install the king pin bush (2) with NEW kingpin (1) on the swivel (3), fix the kingpin in the correct position using the bolt CH-49859-4 (4).
4. Place the locking tool on the kingpin and remove the spacer (5).
5. Install the steering knuckle with holder CH-49859-2 and bracket CH-49859-3 in a hydraulic press (1), then carefully press the kingpin (2) into the pivot (3). Remove the kingpin bolt until it stops by approximately 10 mm.
6. Remove all special tools.
7. Install kingpin bolt (1) and tighten to 7 Nm.
8. Insert the upper ball joint of the steering knuckle (5) into the suspension fork.
9. Install and hand-tighten new bolts (1, 3) and nuts (2, 4) securing the upper ball joint of the steering knuckle. After installation, check and adjust the wheel alignment (see paragraph 22), then tighten the camber adjustment nut (2) torque 70 Nm + 45°+ 15°, and the fastenings of the upper ball joint (3, 4) torque 115 Nm + 45°+ 15°.
Note. Make sure that the upper ball joint of the steering knuckle is correctly aligned with the steering knuckle.
10. Place new steering knuckle assembly with kingpin bushing (1) into the front suspension fork.
11. Install nuts (1) king pin bushings and tighten to 70 Nm.
12. Install a new nut of the upper ball joint of the steering knuckle and tighten with a key CH-49375 to 45 Nm, then tighten another 30°and another 15°.
13. Remove suspension yoke assembly from vise.
14. Install wheel hub with bearing.
15. Install the suspension strut on the fork.
16. Install the front wheel speed sensor.
17. Install the front brake disc.
18. Install the lower suspension arm outer mount.
19. Install the tie rod end on the steering knuckle.
20. Install the front wheel on the car.
21. Lower the car.
22. Check and adjust wheel alignment.
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