FRONT SUSPENSION 3D-1

SECTION 3D

FRONT SUSPENSION
NOTE:

All front suspension fasteners are an important attaching part in that it could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a re-
placement part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to assure proper retention of this part.
There is to be no welding as it may result in extensive damage and weakening of the metal.

Never attempt to heat, quench or straighten any front suspension part, or damage to the part may result.

3D
CONTENTS

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GENERAL DESCRIPTION . . . . . . . . . . . . . . . . 3D- 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 3D- 5
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D- 3 Strut Assembly . . . . . . . . . . . . . . . . . . . . . . 3D- 5
Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . 3D- 3 Stabilizer Bar and/or Bushings . . . . . . . . . 3D-10
Stabilizer Bar and/or Bushing Check . . . . 3D- 3 Wheel Hub, Wheel Stud and
Strut Assembly Check . . . . . . . . . . . . . . . . 3D- 3 Wheel Bearing Outside Inner Race . . . . 3D-12
Suspension Control Arm and Suspension Control Arm/Bushing . . . . . . . 3D-15
Bushing Check . . . . . . . . . . . . . . . . . . . . . 3D- 4 Knuckle and Bearing . . . . . . . . . . . . . . . . . 3D-18
Suspension Control Arm Joint REQUIRED SERVICE MATERIAL . . . . . . . . . 3D- 21
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D- 4 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 3D-21
Wheel Disc, Nut and Bearing Check . . . . 3D- 4
3D-2 FRONT SUSPENSION

GENERAL DESCRIPTION
Front suspension is Macpherson (strut) type independent suspension system, and consists of coil springs, front
suspension struts, steering knuckles, stabilizer bar, and front suspension arms.

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1. Front coil spring

2. Front suspension strut
3. Steering knuckle
4. Stabilizer bar
5. Front suspension control arm
 FRONT SUSPENSION 3D-3

DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 3.

STABILIZER BAR AND/OR BUSHING CHECK

Bar
Inspect for damage or deformation. If defective, replace.

Bushing
Inspect for damage, wear or deterioration. If defective, replace.

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STRUT ASSEMBLY CHECK

Inspect strut for oil leakage. If strut is found faulty, replace it as
an assembly unit, because it can not be disassembled.

Strut function check
Check and adjust tire pressures as specified. Bounce vehicle
body three or four times continuously by pushing front end on the
side with strut to be checked. Apply the same amount of force at
each push and note strut resistance both when pushed and re-
bounding.
Also, note how many times vehicle body rebounds before com-
ing to stop after hands are off. Do the same for strut on the other
side.
Compare strut resistance and number of rebound on the right
with those on the left. And they must be equal in both. With proper
strut, vehicle body should come to stop the moments hands are
off or after only one or two small rebounds. If struts are sus-
pected, compare them with known good vehicle or strut.

Inspect for damage or deformation.

Inspect bearing for wear, abnormal noise or gripping.

Inspect spring seat for cracks or deformation.

Inspect bump stopper for deterioration.

Inspect rebound stopper and strut mount for wear, cracks or de-
formation.

Replace any parts found defective.

3D-4 FRONT SUSPENSION

SUSPENSION CONTROL ARM AND

BUSHING CHECK
Inspect for cracks, deformation or damage.

SUSPENSION CONTROL ARM JOINT CHECK

Check for smooth rotation.

Inspect ball stud for damage.

Inspect dust cover for damage.
NOTE:
Suspension control arm and arm joint cannot be separated
as shown “A” in figure.

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If there is any damage to either, control arm assembly must be re-
placed as a complete unit.

WHEEL DISC, NUT AND BEARING CHECK

Inspect each wheel disc for dents, distortion and cracks.
A disc in badly damaged condition must be replaced.

Check wheel nuts for tightness and, as necessary, retighten
them to specification.
Tightening Torque
(a): 55 N·m (5.5 kg-m, 39.5 lb-ft)

Check wheel bearing for wear. When measuring thrust play, ap-
ply a dial gauge to wheel hub.
Thrust play limit: 0.0 mm (0.000 in.)
If measurement exceeds limit when shaft nut is tightened to spe-
cified torque, replace bearing.
Tightening torque for drive shaft nut
175 N·m (17.5 kg-m, 127.0 lb-ft)

By rotating wheel actually, check wheel bearing for noise and

smooth rotation. If defective, replace bearing.
 FRONT SUSPENSION 3D-5

ON-VEHICLE SERVICE
STRUT ASSEMBLY

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1. Strut nut
2. Strut lock washer
3. Strut inner support
4. Strut rebound stopper
5. Strut support
6. Strut mount
7. Strut mount seat
8. Strut bearing seat
9. Strut bearing
10. Spring upper seat
11. Strut spring seat
12. Bump stopper
13. Coil spring
14. Strut assembly
15. Strut bearing dust seal
16. Strut bracket bolt:
Insert from vehicle front side.
17. Strut bracket nut
18. Strut support nut

: Tightening Torque
3D-6 FRONT SUSPENSION

REMOVAL
1) Hoist vehicle, allowing front suspension to hang free.
2) Remove wheel.
3) Remove E ring (1) securing brake hose and take brake hose off
strut bracket as shown.

4) Remove strut bracket bolts (1).

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5) Remove strut support nuts (1).
Hold strut by hand so that it will not fall off.

6) Remove strut.
 FRONT SUSPENSION 3D-7

DISASSEMBLY
1) Placing special tool to spring as shown, turn special tool bolts
alternately until spring tension is released. Whether it is re-
leased or not can be known by whether strut turns lightly while
strut spring is held stationary.
Special Tool
(A): 09940-71430

2) While keeping spring compressed with special tool as shown

above, remove strut nut and then disassemble parts.

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ASSEMBLY
1) Compress spring with special tool until total length becomes
about 280 mm (11.0 in.) as shown.
Special Tool
(A): 09940-71430
Length “a”: 280 mm (11.0 in.)

2) Mate spring end with stepped part of lower seat (1) as shown.
3D-8 FRONT SUSPENSION

3) Install bump stopper onto strut rod. For installing direction, refer
to the figure on previous page.
4) Pull strut rod as far up as possible and use care not to allow it
to retract into strut.

5) Install spring seat (2), mating stepped part of seat with spring
upper end (1) as shown. And then similarly install spring upper
seat (3) on seat.

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6) Wash strut bearing (8) and apply grease. Install it on spring up-
per seat (9). For installing direction, refer to the figure.
7) Wash bearing seat (7) and install it as shown.
8) On bearing seat and bearing dust seal (12), install mount seat
comp (6), strut mount (5), support (4)-and-rebound stopper (3)
and inner support (2) in this sequence. Be careful for installing
direction. Tighten strut nut (1) to specified torque and then apply
waterproof coating (paint or lacquer) all around nut and strut rod
screw part.
Tightening Torque
(a): 50 N·m (5.0 kg-m, 36.0 lb-ft)
9) Loosen and remove special tool compressing coil spring (10).
While loosening special tool, recheck that stepped part of spring
seat (11) and spring end are in place to each other as described
in foregoing steps 2) and 5).

13. Strut assembly

14. Bump stopper
15. Lock washer
 FRONT SUSPENSION 3D-9

INSTALLATION
1) Install strut by reversing the REMOVAL steps 1) to 6). Insert
bolts in such a direction as shown.
2) Tighten all fasteners to specified torque.
Tightening Torque
(a): 27 N·m (2.7 kg-m, 19.5 lb-ft)
(b): 80 N·m (8.0 kg-m, 58.0 lb-ft)

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3) Install brake hose(1).
Don’t twist hose when installing it.
Install E ring (2) as far as bracket end surface (3) as shown.

4) Tighten wheel nut to specified torque.

Tightening Torque
(c): 55 N·m (5.5 kg-m, 39.5 lb-ft)
5) Confirm front end alignment referring to Section 3A.
3D-10 FRONT SUSPENSION

STABILIZER BAR AND/OR BUSHINGS

1. Split pin
2. Castle nut
3. Stabilizer bar washer
4. Stabilizer bar bush
5. Suspension control arm
6. Stabilizer bar:
Be sure that color paint on stabi-
lizer bar aligns with mount bush,
both right and left.
7. Mount bush:
Install painted side to suspension
control arm on the right.
8. Mount bush bracket
9. Mount bracket bolt

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: Tightening Torque
: Do not reuse.

REMOVAL
1) Hoist vehicle and allow the front lower control arms to hang free.
2) Remove front wheels.
3) Remove split pin and castle nut and then disconnect stabilizer
bar from front suspension arms (right and left) as shown.
4) Remove stabilizer bar mount bush bracket bolts and stabilizer
bar.

INSTALLATION
When installing stabilizer, loosely assemble all components while
insuring that stabilizer centered, side-to-side.
Install parts reversing order of removal, observing following
instructions.

For correct installation of stabilizer bar, side-to-side, be sure that

color paint mark (2) on stabilizer bar aligns with mount bush (1),
both right and left, as shown.
 FRONT SUSPENSION 3D-11

Install painted side to suspension control arm (1) on the right.

Install mount bracket (2) so that its oblong hole drilled side of
bracket to the rear.

Tighten mount bracket bolt (3) to specified torque.
Tightening Torque
(a): 43 N·m (4.3 kg-m, 31.0 lb-ft)
Painted

“A”: Upper side

“B”: Lower side
“C”: Forward

After tightening castle nut (1) to specified torque, be sure to bend

split pin (2) as shown.
Tightening Torque
(b): 65 N·m (6.5 kg-m, 47.0 lb-ft)

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3D-12 FRONT SUSPENSION

WHEEL HUB, WHEEL STUD AND WHEEL BEARING OUTSIDE INNER RACE

1. Steering knuckle 4. Hub bolt

2. Wheel bearing: 5. Wheel hub

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Apply lithic grease (SUZUKI SUPER GREASE A 6. Brake disc bolt
99000-25010) to balls and oil seal lips. 7. Drive shaft castle nut
: Tightening Torque
3. Brake disc

REMOVAL
1) Hoist vehicle and remove wheel.
2) Depress foot brake pedal and hold it there.
Remove drive shaft nut (2) and then loosen brake disc bolts (3)
but don’t remove them.
3) Remove caliper carrier bolts (1).

4) Remove caliper with carrier (1) from knuckle and suspend with
a wire hook (2).
NOTE:
Hang removed caliper with a wire hook or the like so as to
prevent brake hose from bending and twisting excessively
or being pulled.
Don’t operate brake pedal with pads removed.

5) Pull out wheel hub (1) with special tools.

Special Tool
(A): 09943-17912
(B): 09942-15510
6) Separate wheel hub and brake disc.
 FRONT SUSPENSION 3D-13

7) Remove hub bolts (1).

CAUTION:
Never remove bolt unless replacement is necessary.
Be sure to use a new bolt for replacement.

8) Remove wheel bearing inner race (1).

Special Tools
(A): 09913-61110
(B): 09925-88210

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1. Oil hydraulic press INSTALLATION
2. Rod
1) Insert new stud (3) in hub hole. Rotate stud slowly to assure the
serrations are aligned with those made by original bolt.

2) Install outside inner race (1) to wheel hub (2) using special tool.
Installing direction is as shown.
Special Tool
(A): 09940-53111
NOTE:
When replacing bearing, inner race or outer race, be sure
to replace them with new ones as a set.
3D-14 FRONT SUSPENSION

3) Apply grease to outside bearing (1), outside inner race (3) and
oil seal lip (2).
“A”: SUZUKI SUPER GREASE A 99000-25010

4) Install brake disc (1) to wheel hub (2). Tighten disc bolts only
lightly.

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5) Install wheel hub (1) to knuckle by tightening new drive shaft nut.
Do not tap wheel hub.

6) Install carrier and caliper (1).

7) Tighten caliper carrier bolts (2) to specified torque.
Tightening Torque
(d): 85 N·m (8.5 kg-m, 61.5 lb-ft)
8) Depress foot brake pedal and hold it there.
Tighten drive shaft nut (3) and brake disc bolts (4) to specified
torque.
Tightening Torque
(e): 210 N·m (21.0 kg-m, 152.0 lb-ft)
(f): 50 N·m (5.0 kg-m, 36.0 lb-ft)
9) Install wheel and lower vehicle.
 FRONT SUSPENSION 3D-15

SUSPENSION CONTROL ARM/BUSHING

1. Stabilizer bar
2. Ball stud bolt
3. Knuckle
4. Ball stud
5. Stabilizer bar mount bracket bolt
6. Control arm bolt
7. Suspension control arm
8. Stabilizer bar bushing
9. Washer
10. Castle nut
11. Split pin

Forward

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: Tightening Torque
: Do not reuse.

REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove stabilizer bar split pin, castle nut, washer and bushing.
3) Remove stabilizer bar mount bracket (right and left) bolts and
stabilizer bar.
4) Remove ball stud bolt.
5) Remove control arm bolt.
6) Remove control arm.

DISASSEMBLY
Remove bushing with special tool and hydraulic press (1) as
shown.
Special Tool
(A): 09943-77910
3D-16 FRONT SUSPENSION

ASSEMBLY
Before installing bushing (1), apply soap water on its circumfer-
ence to facilitate installation and then installing bushing with spe-
cial tool and hydraulic press (2) as shown.
Special Tool
(A): 09943-77910

CAUTION:
Be sure to use new bushing.

NOTE:
When installed, bush should be equal dimensions “A” and
“B” in figure.

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INSTALLATION
For installation, reverse removal procedure, observing following
instructions.
1) Install ball stud (2) to knuckle (1). Align ball stud groove with
knuckle bolt hole as shown. Then drive in ball stud bolt from the
direction as shown.

2) Install control arm to vehicle body and tighten control arm bolt
to specified torque at the position where control arm is installed
at angle “A” as shown.
Tightening Torque
(a): 65 N·m (6.5 kg-m, 47.0 lb-ft)
Angle “A”: 10_
5_
 FRONT SUSPENSION 3D-17

3) Install stabilizer bar to control arm and then bushing, washer

and nut to stabilizer bar. Tighten nut to the extent to be turned
by hand.
4) Tighten stabilizer bar mount bracket bolts to specified torque.
Before tightening, check if stabilizer bar is properly centered,
side-to-side, refer to STABILIZER BAR AND/OR BUSHINGS in
this section.
5) Tighten all bolts and nuts, refer to illustration on previous page
to each specified torque.
6) Install split pin, refer to STABILIZER BAR AND/OR BUSHINGS
in this section.
7) Install wheel and lower vehicle.
8) Check toe seating, adjust as required referring to Section 3A.

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3D-18 FRONT SUSPENSION

KNUCKLE AND BEARING

REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove wheel hub. Refer to step 2) – 5) of WHEEL HUB,
WHEEL STUD AND WHEEL BEARING OUTSIDE INNER
RACE REMOVAL in this section.

3) Disconnect tie rod end (1) from knuckle (2) with special tool.
Special Tool
(C): 09913-65210

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4) Remove ball stud bolt (1).

5) Remove strut bracket bolts (1), nuts (2) and steering knuckle
(3).

DISASSEMBLY
NOTE:
Once bearing outer race is removed, bearing set (outer race,
bearings and inner races) should be replaced with new one.
1) Remove outside oil seal (1), snap ring (2), outside bearing (3),
inside oil seal (7), inside inner race (6) and inside bearing (5)
from knuckle (4) in that order.
 FRONT SUSPENSION 3D-19

2) Remove bearing outer race using special tool and hydraulic

press (1).
Special Tool
(C): 09913-75520
3) Remove wheel bearing inner race from wheel hub referring to
step 8) of WHEEL HUB, WHEEL STUD AND WHEEL BEAR-
ING OUTSIDE INNER RACE REMOVAL in this section.

ASSEMBLY
1) Press-fit new bearing to knuckle (2) using special tools and hy-
draulic press (1).
Special Tools
(B): 09924-74510
(C): 09944-78210
(D): 09944-68210

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2) Install snap ring.
3) Drive in new outside oil seal (1) until its end contacts snap ring
using special tools.
Special Tools
(B): 09924-74510
(C): 09944-78210
(D): 09944-68210

4) Set steering knuckle (1) to wheel hub (2) as shown and take out
bearing inner race support from bearing.

5) Using special tools and hydraulic press (1), drive wheel hub (2)
into steering knuckle (3) as shown.
Special Tool
(A): 09913-75520
(B): 09944-66020
3D-20 FRONT SUSPENSION

6) Drive in new inside oil seal (1) until seal is flush with stopped sur-
face of knuckle (2) by using special tool.
NOTE:
When driving in oil seal, be careful not to deform or tilt it or
not to cause damage to rubber part.
Special Tool
(C): 09944-78210

INSTALLATION
1) Install knuckle (2) with wheel hub to ball stud (3) on control arm
(4) and strut (1) bracket. Installing direction of each bolt is as
shown. Align knuckle bolt hole with ball stud groove as shown
and install ball stud bolt.
Tightening Torque
(a): 80 N·m (8.0 kg-m, 58.0 lb-ft)

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(b): 55 N·m (5.5 kg-m, 40.0 lb-ft)

2) Connect tie rod end (1) to knuckle (2) and tighten tie rod end
castle nut (3) to specified torque.
Install split pin (4).
Tightening Torque
(c): 43 N·m (4.3 kg-m, 31.0 lb-ft)

3) Tighten new drive shaft nut. Do not tap wheel hub.

4) For installation procedures following the above, refer to steps 6)
– 9) of WHEEL HUB, WHEEL STUD AND WHEEL BEARING
OUTSIDE INNER RACE INSTALLATION in this section.
 FRONT SUSPENSION 3D-21

REQUIRED SERVICE MATERIAL

RECOMMENDED
MATERIAL USE
SUZUKI PRODUCT
SUZUKI SUPER GREASE A
Lithic wheel bearing grease Wheel bearing
(99000-25010)

SPECIAL TOOL

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09913-61110 09913-65210 09913-75520 09924-74510
Bearing puller Tie rod end remover Bearing installer Bearing installer handle

09925-88210 09940-71430 09942-15510 09943-17912

Bearing puller attachment Spring compressor Sliding hammer Front wheel hub remover

09943-77910 09944-68210 09944-78210

Bushing remover Bearing & oil seal installer Bearing installer support