Get Front Suspension Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

FRONT SUSPENSION 3D-1

SECTION 3D

FRONT SUSPENSION

NOTE:

D 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.

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

CONTENTS

GENERAL DESCRIPTION 3D- 2. . . . . . . . . . . . . . . .

DIAGNOSIS 3D- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis Table 3D- 3. . . . . . . . . . . . . . . . . . . . . .

Stabilizer Bar and/or Bushing Check 3D- 3. . . .

Strut Assembly Check 3D- 3. . . . . . . . . . . . . . . .

Suspension Control Arm and

Bushing Check 3D- 4. . . . . . . . . . . . . . . . . . . . .

Suspension Control Arm Joint

Check 3D- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Disc, Nut and Bearing Check 3D- 4. . . .

ON-VEHICLE SERVICE 3D- 5. . . . . . . . . . . . . . . . . .

Strut Assembly 3D- 5. . . . . . . . . . . . . . . . . . . . . .

Stabilizer Bar and/or Bushings 3D-10. . . . . . . . .

Wheel Hub, Wheel Stud and

Wheel Bearing Outside Inner Race 3D-12. . . .

Suspension Control Arm/Bushing 3D-15. . . . . . .

Knuckle and Bearing 3D-18. . . . . . . . . . . . . . . . .

REQUIRED SERVICE MATERIAL 3D-21. . . . . . . . .

SPECIAL TOOL 3D-21. . . . . . . . . . . . . . . . . . . . . . . .

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.

1. Front coil spring

2. Front suspension strut

3. Steering knuckle

4. Stabilizer bar

5. Front suspension control arm

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.

STRUT ASSEMBLY CHECK

D Inspect strut for oil leakage. If strut is found faulty, replace it as

an assembly unit, because it can not be disassembled.

D 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.

D Inspect for damage or deformation.

D Inspect bearing for wear, abnormal noise or gripping.

D Inspect spring seat for cracks or deformation.

D Inspect bump stopper for deterioration.

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

formation.

Replace any parts found defective.

FRONT SUSPENSION 3D-3

SUSPENSION CONTROL ARM AND

BUSHING CHECK

Inspect for cracks, deformation or damage.

SUSPENSION CONTROL ARM JOINT CHECK

D Check for smooth rotation.

D Inspect ball stud for damage.

D Inspect dust cover for damage.

NOTE:

Suspension control arm and arm joint cannot be separated

as shown “A” in figure.

If there is any damage to either, control arm assembly must be re-

placed as a complete unit.

WHEEL DISC, NUT AND BEARING CHECK

D Inspect each wheel disc for dents, distortion and cracks.

A disc in badly damaged condition must be replaced.

D 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)

D 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)

D By rotating wheel actually, check wheel bearing for noise and

smooth rotation. If defective, replace bearing.

3D-4 FRONT SUSPENSION

FRONT SUSPENSION 3D-5

ON-VEHICLE SERVICE

STRUT ASSEMBLY

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

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).

5) Remove strut support nuts (1).

Hold strut by hand so that it will not fall off.

6) Remove strut.

3D-6 FRONT SUSPENSION

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.

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.

FRONT SUSPENSION 3D-7

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.

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

3D-8 FRONT SUSPENSION

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)

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.

FRONT SUSPENSION 3D-9

STABILIZER BAR AND/OR BUSHINGS

: Tightening Torque

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

: 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.

D 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.

3D-10 FRONT SUSPENSION

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

D Install mount bracket (2) so that its oblong hole drilled side of

bracket to the rear.

D 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

D 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)

FRONT SUSPENSION 3D-11

WHEEL HUB, WHEEL STUD AND WHEEL BEARING OUTSIDE INNER RACE

: Tightening Torque

1. Steering knuckle

2. Wheel bearing:

Apply lithic grease (SUZUKI SUPER GREASE A

99000-25010) to balls and oil seal lips.

3. Brake disc

4. Hub bolt

5. Wheel hub

6. Brake disc bolt

7. Drive shaft castle nut

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.

3D-12 FRONT SUSPENSION

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

INSTALLATION

1) Insert new stud (3) in hub hole. Rotate stud slowly to assure the

serrations are aligned with those made by original bolt.

1. Oil hydraulic press

2. Rod

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.

FRONT SUSPENSION 3D-13

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.

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.

3D-14 FRONT SUSPENSION

SUSPENSION CONTROL ARM/BUSHING

: Tightening Torque

: Do not reuse.

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

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

FRONT SUSPENSION 3D-15

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

NOTE:

When installed, bush should be equal dimensions “A” and

“B” in figure.

CAUTION:

Be sure to use new bushing.

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_

3D-16 FRONT SUSPENSION

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.

FRONT SUSPENSION 3D-17

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

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.

3D-18 FRONT SUSPENSION

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

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

FRONT SUSPENSION 3D-19

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)

(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.

3D-20 FRONT SUSPENSION

09913-65210

Tie rod end remover

09924-74510

Bearing installer handle

09943-77910

Bushing remover

09943-17912

Front wheel hub remover

09942-15510

Sliding hammer

09940-71430

Spring compressor

09913-61110

Bearing puller

09913-75520

Bearing installer

09925-88210

Bearing puller attachment

09944-68210

Bearing & oil seal installer

09944-78210

Bearing installer support

FRONT SUSPENSION 3D-21

REQUIRED SERVICE MATERIAL

MATERIAL

RECOMMENDED

SUZUKI PRODUCT

USE

Lithic wheel bearing grease

SUZUKI SUPER GREASE A

(99000-25010)

Wheel bearing

SPECIAL TOOL

Front Suspension for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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