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Damper/Spring Replacement: Reassembly

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.
  1. Install the dust cover end inside the top of the dust cover sleeve, and install the dust cover lower mount on the bottom of the dust cover sleeve.
  2. Install the bump stop on the damper shaft, then install the set of the dust cover (assembled in step  1) over it.
  3. Install the rest of the parts except for the washer and self-locking nut onto the damper unit referring to the Exploded View. Align the spring bottom end (A), the stepped part of the dust cover lower mount (B), and the step on the lower spring seat (C).
    Fig 1: Aligning Spring Bottom End
    G03682404Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Install the damper assembly on a commercially available strut spring compressor (D).
  5. Compress the damper spring with the strut spring compressor.
  6. Install a new washer (A) and a new self-locking nut (B) on the damper shaft.
    Fig 2: Installing Washer And Self-Locking Nut With Torque Specifications
    G03682405Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Hold the damper shaft with a hex wrench (C), and tighten the self-locking nut to the specified torque value.
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