Damper/Spring Replacement: Installation

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2006 Honda Insight, 2005 Honda Insight, 2004 Honda Insight, 2003 Honda Insight, and 2002 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.

Lower the lower arm, and position the damper assembly (A) in the body.

Fig 1: Positioning Damper Assembly In Body And Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Loosely install new self-locking nuts (B) onto the top of the damper.
Position the damper bottom on the knuckle, install the new damper pinch bolts (A) and nuts (B), and lightly tighten the bolts.

Fig 2: Installing Damper Pinch Bolts And Nuts With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Connect the stabilizer link to the damper, and lightly tighten the nuts.
Place a jack with a wood block under the lower arm ball joint, and raise the suspension to load the suspension.
Tighten the flange nuts on the top of the damper to the specified torque value.
Tighten the damper pinch bolts to the specified torque value.
Connect the stabilizer link (A) to the damper, and tighten the flange nut (B) while holding the joint pin (C) with a hex wrench (D).

Fig 3: Connecting Stabilizer Link To Damper And Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Connect the tie-rod to the steering arm, and tighten the nut (A) to the specified torque value. Install the new cotter pin (B) after tightening, and bend its end as shown.

Fig 4: Installing Cotter Pin And Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the brake hose bracket and the flange bolt to the damper, and tighten the bolt to the specified torque value.
Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels.
Check the wheel alignment, and adjust it if necessary (see WHEEL ALIGNMENT ).