DOWNLOAD 1991-2009 Honda Accord Suspension HOW INSTALL-REMOVE GUIDE

1991-2009 Honda Accord/Coupe Front Suspension, Bearing, Hub, Knuckle, Specifications, Removal, Installation, Lubrication, Diagrams, Troubleshooting & Repair for 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 & 2009 Accord/Coupe Models.

1991-2009 Honda Accord Front Suspension

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1991-1993 Models covered in this Honda Accord Shop Manual: 1991, 1992 and 1993 Honda Accord, 1991, 1992, 1993 Honda Accord Aero Deck and 1992 Honda Accord Coupe. Engines Covered in this manual are: F18A F20A F22A

1994-1997 Service Manual Model/Year Applications: Honda Accord Coupe 2 Door: 1994, 1995, 1996, 1997 DX, LX, EX, ES, LS, iES, iLS, Engine Type: F22B1 2.2 SOHC (VTEC) Sequential Multi-Port Fuel Injected engine. Egnine Type: F22B2 2.2 -F20B3 2.0 - F22B5 2.2 SOHC Sequential Multi-Port Fuel Injected Engine (VTEC & Non-VTEC).

1998-2002 Honda Accord EX, LX, DX, LX V6, EX V6 Models with 2.3L 150 hp I4 & 3.0L 200 hp V6 engines

2003-2007 Honda Accord Service Manual Application: This Manual Covers all 2003-2007 Honda Accord USA & Canada Models 2003, 2004, 2005, 2006, 2007, Honda Accord LX, EX, DX, 2.4L & 3.0L 4 & 6 cylinder models, 2.4L 160 hp, 3.0L 240 hp.

2008-2009 Exact Models Covered In This Service Manual: (THIS MANUAL COVERS ALL 2008-2009 HONDA ACCORDS and COUPE), 2008 4 Door Model (Accord), 2008 2 Door Model (Accord Coupe / K24Z3), 2009 Accord / K24Z2, K24Z3, 2008 08' 4 Door Sedan 5 Speed Manual, 2008 08' 4 Door Sedan 5 Speed Automatic, 2008 2 Door Coupe/5-Speed Manual, 2008 2 Door Coupe/5-Speed Manual, 2009 09' 4-2 Door Sedan 5 Speed Manual, 2009 09' 4-2 Door Sedan 5 Speed Automatic, 2009 09' 4-2 Door Honda Accord Coupe/K24-Z3, LX (L X), EX (E X), EX-L models.

2008-2009 Honda Engines Covered: 2008 K24, K-24, K24Z2, 2.4L DOHC i-VTEC Sequential Multiport Fuel Injected, 177HP Engine, 2008 K24, K-24, K24Z3, 2.4L DOHC i-VTEC Sequential Multiport Fuel Injected, 190HP Engine, 2008 K24, K-24, K24A3, 2.4L DOHC i-VTEC Sequential Multiport Fuel Injected, 190HP Engine, 2009 K24, K-24, K24Z2, 2.4L DOHC i-VTEC Sequential Multiport Fuel Injected, 177HP Engine, 2009 K24, K-24, K24Z3, 2.4L DOHC i-VTEC Sequential Multiport Fuel Injected, 190HP Engine, 88E5 - 5-Speed Manual, M91A - 5 Speed Automatic, B90A - 5 Speed Automatic.

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FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION

This vehicle has a gas pressurized MacPherson strut type front suspension design (Fig. 1). The front suspension includes the following components:

² Hub
² Bearing
² Lower control arm
² Stabilizer bar
² Steering knuckle
² Strut assembly

For more information on the description and operation of an individual component, refer to the applicable component.

OPERATION - FRONT SUSPENSION

The front suspension allows each front wheel on a vehicle to adapt to different road surfaces and conditions without greatly affecting the opposite wheel and the ability to control the vehicle. Each side of the front suspension is allowed to pivot so the vehicle can be steered in the direction preferred. When a vehicle strikes a bump, the force is transferred through the hub, bearing, and knuckle, into the strut assembly to absorb the force and dampen it. During steering maneuvers, the strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint
mounted on the lower control arm) turn as an assembly.

WARNINGS AND CAUTIONS

WARNING: DO NOT REMOVE THE STRUT SHAFT NUT WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE THE COIL SPRING IS COMPRESSED WITH A COMPRESSION TOOL. THE SPRING IS HELD UNDER HIGH PRESSURE.

CAUTION: Only frame contact hoisting equipment can be used on this vehicle. All vehicles have a fully independent rear suspension. The vehicles
cannot be hoisted using equipment designed to lift a vehicle by the rear axle. If this type of hoisting equipment is used, damage to rear suspension components will occur.

CAUTION: At no time when servicing a vehicle can a sheet metal screw, bolt, or other metal fastener be installed in the shock tower to take the place of an original plastic clip. It may come into contact with the strut or coil spring.

CAUTION: Wheel bearing damage will result if after loosening the hub nut, the vehicle is rolled on the ground or the weight of the vehicle is allowed to be
supported by the tires for a length of time.

STANDARD PROCEDURE - LUBRICATION

There are no serviceable lubrication points on the front suspension. The front lower ball joints have grease fittings which have had the head snapped off
by the manufacturer after they have been filled. This has been done to eliminate the possibility of damaging the non-vented seals. Grease will not leak from the broken grease fittings. The ball joints are sealed for life and require no maintenance.

CAUTION: No attempt should be made to replace the ball joint grease fitting with a new fitting, then filling the ball joint with grease. Damage to the grease seal can result.

1 - VEHICLE STRUT TOWER
2 - OUTER TIE ROD
3 - STEERING GEAR
4 - STRUT ASSEMBLY
5 - JAM NUT
6 - LOWER CONTROL ARM
7 - CROSSMEMBER
8 - BALL JOINT
9 - STABILIZER BAR
10 - STABILIZER BAR CUSHION AND RETAINER
11 - STABILIZER BAR LINK
12 - HUB
13 - KNUCKLE
14 - STRUT
15 - LOWER SPRING ISOLATOR
16 - COIL SPRING
17 - JOUNCE BUMPER
18 - DUST SHIELD
19 - SPRING SEAT AND BEARING
20 - UPPER MOUN

SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE

DESCRIPTION TORQUE
STRUT ASSEMBLY:

Tower Nuts 34 N·m (300 in. lbs.)
Steering Knuckle Nuts 54 N·m (40 ft. lbs.) + 90° Turn
Strut Shaft Nut 75 N·m (55 ft. lbs.)

STEERING KNUCKLE:

Ball Joint Stud Pinch Bolt Nut 95 N·m (70 ft. lbs.)
Disc Brake Caliper Adapter Mounting Bolts - 104 N·m (77 ft. lbs.)
Disc Brake Caliper Guide Bolts 22 N·m (192 in. lbs.)
Disc Brake Caliper Guide Bolts - 35 N·m (26 ft. lbs.)

WHEEL BEARING AND HUB:

Bearing Retainer Plate Bolts 28 N·m (250 in. lbs.)
Driveshaft Hub Nut 244 N·m (180 ft. lbs.)
Wheel Mounting Nuts 135 N·m (100 ft. lbs.)

STEERING GEAR:

Crossmember Bolts 68 N·m (50 ft. lbs.)
Tie Rod Adjusting Jam Nut 75 N·m (55 ft. lbs.)
Tie Rod End Steering Knuckle Nut 54 N·m (40 ft. lbs.)'

LOWER CONTROL ARM:

Front Pivot Bolt 163 N·m (120 ft. lbs.)
Rear Pivot Bolt 237 N·m (175 ft. lbs.)

STABILIZER BAR:

Cushion Retainer Bolts 28 N·m (250 in. lbs.)
Link Nut 31 N·m (275 in. lbs.)

SPECIAL TOOLS
FRONT SUSPENSION

Socket/Wrench, Strut Nut 6864
Remover 6804
Installer 6758
Remover/Installer 6908 (–2)

HUB / BEARING
DESCRIPTION

The wheel bearing and hub are pressed into the steering knuckle. (Refer to 2 - SUSPENSION/ FRONT/KNUCKLE - DESCRIPTION) OPERATION
The wheel bearing and hub are pressed into the steering knuckle. (Refer to 2 - SUSPENSION/ FRONT/KNUCKLE - OPERATION)

DIAGNOSIS AND TESTING - WHEEL BEARING AND HUB

The wheel bearing is designed for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions during diagnosis, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced.

Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing.

REMOVAL

The wheel bearing and hub are pressed into the knuckle. (Refer to 2 - SUSPENSION/FRONT/ KNUCKLE - REMOVAL)

INSTALLATION

The wheel bearing and hub are pressed into the knuckle. (Refer to 2 - SUSPENSION/FRONT/ KNUCKLE - INSTALLATION)

KNUCKLE
DESCRIPTION

The steering knuckle is a single casting with legs machined for attachment to the front strut assembly on the top, lower control arm ball joint on the bottom, and steering linkage on the trailing end (Fig. 1). The steering knuckle also has two machined abutments (rails) on the leading end casting to support and align the front disc brake caliper. The knuckle supports the wheel bearing and hub (Fig. 1). The wheel hub is pressed into a sealed-forlife
wheel bearing that is pressed into the steering knuckle. A retainer plate also holds the bearing in place. The hub supports the driveshaft outer constant
velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a nut retainer and cotter pin. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub has five studs pressed into its flange.

OPERATION

The steering knuckle pivots with the strut assembly between the lower ball joint and the pivot bearing in the strut assembly. The steering gear outer tie rod end connects to the trailing end of each knuckle, allowing the vehicle to be steered. The center of the knuckle supports the hub, wheel bearing and axle shaft. The hub and wheel bearing work together. The wheel bearing has internal bearings that allow the hub to rotate with the driveshaft and the tire and wheel assembly. The hub’s five studs mount the tire and wheel to the vehicle.

DIAGNOSIS AND TESTING - STEERING KNUCKLE

The front suspension steering knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way.
If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the steering knuckle.

REMOVAL

NOTE: Before proceeding with this procedure, (Refer to 2 - SUSPENSION/FRONT - WARNING).

(1) Apply the brakes and hold in place.
(2) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE).
(3) Remove the front tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
(4) Remove the cotter pin, lock nut and spring washer from the hub nut (Fig. 2).
(5) While the brakes are applied, loosen and remove the hub nut (Fig. 2).
(6) Release the brakes.

1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Honda Accord VTEC, I-VTEC, 1.6L, 18.L, 2.0L, 2.2L, 2.4L Non-V-TEC