Canada - Suspension - Front Suspension Tapping Noise

Bulletin
1126

Issue Date
2002-10-14

Reference
FS-02-001

Model
Corolla, Matrix

Year Range
2003

Market
Canada

Component
FS

Subject:
FRONT UPPER SUSPENSION NOISE

Some 2003 Corolla and Matrix model year vehicles may exhibit a tapping noise from the front upper suspension area. Occasionally this noise may be interpreted as an instrument panel rattle noise. Use the following instructions to repair the noise.

APPLICABLE VEHICLES: 2003 model year Corolla & Matrix vehicles produced before the following VIN:







PRODUCTION CHANGE INFORMATION:







PARTS INFORMATION:

REPAIR PROCEDURE:
1. Remove Front Wheel







2. Disconnect Front Stabilizer Link Assembly
Remove the nut and disconnect the front stabilizer link assembly from the front shock absorber assembly.

HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.







3. Disconnect Front Flexible Hose

a) W/ABS:
Remove the bolt, disconnect the brake flexible hose and front speed sensor.

b) W/O ABS:
Remove the bolt, disconnect the brake flexible hose.







4. Remove Front Shock Absorber With Coil Spring

a) Remove the 2 bolts and nuts on the lower side of the front shock absorber assembly.

NOTE:
When removing the bolt, stop the bolt from rotating and loosen the nut.







b) Remove the 3 nuts on the upper side of the front shock absorber assembly.
c) Remove the front shock absorber with the coil spring.







5 Prepare insulating Material
a) Locate the 2 EPT Sealer in the Wind Noise Kit (P/N 08231-00810)
b) Cut 3 pieces of EPT Sealer per side of vehicle (6 pieces total) to the following dimensions:

EPT Dimensions:
L: 100 mm (4in.)
W: 13 mm (0.5 in.)
T: 2 mm (0.08 in.)







6. Apply EPT Sealer to Upper Suspension Mount

NOTE:
Avoid applying the EPT Sealer within 15 mm (0.6 in.) from the edge of the upper suspension mount bolts.







7. Install Front Shock Absorber With Coil Spring
a) Install the shock absorber with the two bolts.
b) Install the 3 nuts to the upper side of the front shock absorber with coil spring.

Torque: 39 N-m (398 kgf-cm, 29 ft-lbs)







c) Secure the 2 bolts with nuts to the lower side of the front shock absorber with coil spring.

Torque:
Corolla -153 N-m (1560 kgf-cm, 113 ft-lbs)
Matrix - 220 N-m (2243 kgf-cm, 162 ft-lbs)

NOTE:
When installing the bolt, stop the bolt from rotating and torque the nut.







8. Install Front Flexible Hose
a) A. W/ABS:
Install the brake flexible hose and front speed sensor with the bolt.
Torque: 29 N-m (296 kgf-cm, 21 ft-lbs)

b) W/O ABS:
Install the brake hose with the bolt.
Torque: 29 N-m (296 kgf-cm, 21 ft-lbs)







9. Install Front Stabilizer Link Assembly
Install the front stabilizer link assembly with the nut.

Torque: 74 N-m ( 755 kgf-cm, 55 ft-lbs)

NOTE:
If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

10. Install Front Wheel

Torque: 103 N-m (1,050 kgf-cm, 76 ft-lbs)

11. Inspect and Adjust Front Wheel Alignment







REPAIR TIME:

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.