1998-2003 Suzuki Alto 4 Door Rear Suspension (Coil Spring Type) User Manual
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Rear Suspension (Coil Spring Type) for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

3E1
REAR SUSPENSION 3E1-1
SECTION 3E1
REAR SUSPENSION
(COIL SPRING TYPE)
NOTE:
D All rear 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 excessive damage and weakening of the metal.
D Never attempt to heat, quench or straighten any suspension part, or damage to the part may result.
CONTENTS
GENERAL DESCRIPTION 3E1- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS 3E1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3E1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Shock Absorber Check 3E1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Arm, Lateral Rod, Rear Axle and Coil Spring Check 3E1- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bump Stopper/Spring Upper Seat Check 3E1- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Disc, Nut and Bearing Check 3E1- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 3E1- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod 3E1- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Shock Absorber 3E1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Arm and Bush 3E1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bearing and Wheel Stud 3E1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle 3E1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS 3E1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3E1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
Rear suspension consists of coil springs, rear axle, shock absorbers, lateral rod and trailing arms.
The lateral rod is installed to the body and axle by using bushes so as to prevent axle movement in the lateral
direction.
The trailing arms which are connected with the axle are installed to the body by using a bush so that axle moves
up and down with the bush as its supporting point.
The shock absorber is installed between the body and axle to absorb up-and-down movement of the vehicle body.
1. Rear coil spring
2. Rear bump stopper
3. Rear spring upper seat
4. Rear shock absorber
5. Lateral rod
6. Trailing arm
7. Rear axle
8. Wheel bearing
9. Brake drum
10. Spindle cap
11. Spindle nut
12. Shock absorber lower bolt:
Install bolt from the center of
the vehicle toward the outside.
13. Lateral rod bolt:
Install bolt from the front side
of the vehicle toward the rear
side.
: Tightening Torque
14. Trailing arm front bolt:
Install bolt from the center of the ve-
hicle toward the outside.
15. Shock absorber upper bolt:
Install bolt from the outside of the ve-
hicle toward the inside.
16. Trailing arm rear bolt:
Install bolt from the center of the ve-
hicle toward the outside.
17. Shock absorber upper nut
18. Lateral rod body side nut
19. Lateral rod axle side nut
3E1-2 REAR SUSPENSION
1. Rear coil spring
2. Rear bump stopper
3. Rear spring upper seat
4. Rear shock absorber
5. Lateral rod
6. Trailing arm
7. Bush
8. Rear axle:
Apply water tight sealant 366E
99000-31090 to joint seam of axle and
brake back plate.
9. Bearing
10. Spacer
11. Brake drum
12. Split pin
13. Castle nut
14. Spindle cap
: Tightening Torque
: Do not reuse
REAR SUSPENSION 3E1-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 3.
REAR SHOCK ABSORBER CHECK
D Inspect for deformation or damage.
D Inspect bushings for wear or damage.
D Inspect for evidence of oil leakage.
Replace any defective part.
WARNING:
When handling rear shock absorber in which high pres-
sure gas is sealed, make sure to observe the following
precautions.
1) Don’t disassemble it.
2) Don’t put it into the fire.
3) Don’t store it where it gets hot.
4) Before disposing it, be sure to drill a hole in it where
shown by an arrow in figure and let gas and oil out.
Lay it down sideways for this work.
5) The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill. There-
fore, be sure to wear goggle.
Drill hole with
approximately 3 mm
(0.12 in.) diameter.
TRAILING ARM, LATERAL ROD, REAR AXLE
AND COIL SPRING CHECK
D Inspect for cracks, deformation or damage.
D Inspect bushing for damage, wear or breakage.
Replace any defective part.
3E1-4 REAR SUSPENSION
BUMP STOPPER/SPRING UPPER SEAT
CHECK
D Inspect for cracks, deformation or damage.
Replace any defective part.
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 hub nuts for tightness and, as necessary, retighten
to specification.
Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
D Check wheel bearings for wear. When measuring thrust play,
apply a dial gauge to drum center after removing wheel center
cap from wheel disc.
Thrust play limit “a”: 0.3 mm (0.012 in.)
When measurement exceeds limit, replace bearing.
D By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If it is defective, replace bearing.
REAR SUSPENSION 3E1-5
ON-VEHICLE SERVICE
LATERAL ROD
REMOVAL
1) Hoist vehicle.
2) Remove lateral rod nuts (1) and bolt (2).
3) Remove lateral rod (3).
INSTALLATION
1) Install lateral rod (1) to rear axle (2) and vehicle body (3) refer-
ring to figure for proper installing direction of nuts (4), bolt (5)
and washer (6).
Tighten nuts temporarily at this step.
FORWARD
Rear axle side Body side
2) Lower hoist.
3) Tighten lateral rod nuts (1) to specified torque. It is the most de-
sirable to have vehicle off hoist and in nonloaded condition
when tightening them.
Tightening Torque
(a): 45 N·m (4.5 kg-m, 32.5 lb-ft)
(b): 58 N·m (5.8 kg-m, 42.0 lb-ft)
3E1-6 REAR SUSPENSION
REAR SHOCK ABSORBER
REMOVAL
1) Hoist vehicle.
2) Support center of rear axle by using floor jack to prevent it from
lowering.
3) Remove lower mounting bolt (1).
4) Remove upper mounting bolt (2) and nut (3). Then remove
shock absorber (4).
INSTALLATION
1) Install shock absorber (4) referring to the figure.
2) Tighten bolts to specified torque.
Tightening Torque
(a): 58 N·m (5.8 kg-m, 42.0 lb-ft)
3) Lower vehicle.
TRAILING ARM AND BUSH
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support center of rear axle (2) by using floor jack (1) to prevent
it from lowering.
CAUTION:
Never apply floor jack against lateral rod as it may get
deformed.
3) Remove rear shock absorber lower mounting bolt (1).
4) Remove trailing arm rear mounting bolts.
REAR SUSPENSION 3E1-7
5) Loosen trailing arm front bolt (1) and remove trailing arm.
6) Remove trailing arm bushes (1) by using hydraulic press and
special tools.
Special Tool
(A): 09924-74510
Front side (B): 09951-16060
Rear side (C): 09951-16030
INSTALLATION
1) Press fit bushes by using hydraulic press and special tools.
Special Tool
(A): 09924-74510
Front side (B): 09951-16060
Rear side (C): 09951-16030
NOTE:
When installing front side bush (2) into trailing arm (1), di-
rect its slit (3) side toward front and rear.
2) Install trailing arm (1) front side to body, and then insert bolt (2).
3) Install trailing arm rear side to rear axle (3) and tighten trailing
arm rear nut (4) to specified torque.
Tightening Torque
(a): 80 N·m (8.0 kg-m, 58.0 Ib-ft)
4) Tighten shock absorber lower mounting bolt (5) to specified
torque.
Tightening Torque
(b): 58 N·m (5.8 kg-m, 42.0 Ib-ft)
5) Tighten trailing arm front nut (2) to specified torque.
Tightening Torque
(c): 80 N·m (8.0 kg-m, 58.0 Ib-ft)
3E1-8 REAR SUSPENSION
6) Install wheel (1) and tighten wheel nuts (2) to specified torque.
Tightening Torque
(d): 55 N·m (5.5 kg-m, 40.0 lb-ft)
7) Lower vehicle.
WHEEL BEARING AND WHEEL STUD
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Remove spindle cap (1) as shown by hammering lightly at 3
locations around it so as not to deform or cause damage to seat-
ing part of cap.
3) Remove split pin (1), castle nut (2) and washer (3).
REAR SUSPENSION 3E1-9
4) Release parking brake lever (1) to cancel rear brake.
5) Loosen parking brake cable lock nuts (2).
FRONT
6) Pull brake drum (1) off by using special tools.
Special Tool
(A): 09942-15510
(B): 09943-17912
7) Remove wheel bearing (1).
8) Remove wheel stud (1) by using hydraulic press (2) and general
rod (3).
3E1-10 REAR SUSPENSION
INSTALLATION
1) Insert new stud (1) in drum (4) hole after rotate stud slowly to
assure the serrations are aligned with those mode by the origi-
nal bolt by using hydraulic press (3) and general rod (2).
2) Install wheel bearing by using special tool.
Special Tool
(A): 09913-76010
NOTE:
When installing bearings:
D Direct stamped side of bearing towards outside.
D Refer to figure for installing direction of spacer (2).
D Direct inner bearing sealed side (1) outward.
D Fill the space indicated by “A” in figure with bearing
grease as much as 40% of space capacity.
D Install outer bearing (3) so that resin side of its retainer
faces toward the outside of vehicle body.
3) Before installing brake drum, to maximize clearance between
shoe and drum, turn strut adjuster to the direction as shown in
figure.
4) Install brake drum (1), washer and axle castle nut.
5) Tighten castle nut (2) to specified torque.
Tightening Torque
(a): 100 N·m (10.0 kg-m, 72.5 Ib-ft)
REAR SUSPENSION 3E1-11
6) Install split pin (1) securely as shown.
7) Install spindle cap.
NOTE:
D When installing spindle cap, hammer lightly several
locations on the collar of cap until the collar comes
closely into contact with brake drum.
D If fitting part of cap is deformed or damaged or if it is
fitted loosely, replace with new one.
8) Tighten wheel nuts to specified torque.
Tightening Torque
(b): 55 N·m (5.5 kg-m, 40.0 lb-ft)
9) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load two to three times so as to obtain proper
drum-to-shoe clearance.
10) Check to make sure that brake drum is free from dragging and
brake works properly. Then remove vehicle from lift and per-
form brake test.
3E1-12 REAR SUSPENSION
REAR AXLE
NOTE:
In removing and installing the rear axle, the same procedure
is required on both the right and left sides. The procedure de-
scribed here is a representative one. If it is used on one side,
it must be used in symmetry on the other side.
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Pull brake drum. (Refer to steps 2) to 6 on WHEEL BEARING
AND WHEEL STUD in this section.)
3) From bracket on axle, remove E-ring (1).
4) Disconnect brake pipe flare nut (1) from wheel cylinder (2).
5) Put breeder plug cap (3) on to brake pipe (4) to prevent brake
fluid outflow.
6) Remove brake hose/pipe from bracket on axle.
7) Remove rear brake back plate bolts (1) and remove back plate
from axle (2).
8) Support center of rear axle (2) by using floor jack (1).
REAR SUSPENSION 3E1-13
9) Remove lateral rod.
10) Remove shock absorber lower mount bolt (1).
11) Loosen trailing arm front nut (2).
12) Lower rear axle by releasing floor jack gradually till tension of
suspension spring is relieved, and then remove spring.
13) Remove trailing arm front bolt and take down rear axle with
trailing arm.
14) Remove trailing arm from rear axle.
INSTALLATION
1) Install trailing arm (1) to rear axle (2).
2) Install trailing arm with its front side to body.
3E1-14 REAR SUSPENSION
3) Support rear axle (1) by using floor jack.
4) Install coil spring (3) on rear axle spring seat (2).
NOTE:
D When installing coil spring, insert it with its flat face side
to top.
D When seating coil spring, mate spring end with stepped
part (4) of rear axle seat as shown.
5) Tighten trailing arm rear nut (1) to specified torque.
Tightening Torque
(a): 80 N·m (8.0 kg-m, 58.0 Ib-ft)
6) Install shock absorber lower mounting bolt (2) and tighten it to
specified torque.
Tightening Torque
(b): 58 N·m (5.8 kg-m, 42.0 Ib-ft)
7) Tighten trailing arm front nut (3) to specified torque.
Tightening Torque
(c): 80 N·m (8.0 kg-m, 58.0 Ib-ft)
8) Install lateral rod (4) and tighten nuts to specified torque.
Tightening Torque
(d): 45 N·m (4.5 kg-m, 32.5 Ib-ft)
(e): 58 N·m (5.8 kg-m, 42.0 Ib-ft)
Upper side
REAR SUSPENSION 3E1-15
9) Apply water tight sealant to joint seam of axle and brake back
plate and tighten bolts to specified torque.
“A” : Sealant 366E, 99000-31090
Tightening Torque
(f): 23 N·m (2.3 kg-m, 16.5 Ib-ft)
10) Put brake flexible hose (1) to bracket on axle and secure it with
E-rings (4) and remove breather plug cap from end of pipe.
Then tighten pipe flare nut (2) to wheel cylinder (3) to specifica-
tion.
Tightening Torque
(g): 12 N·m (1.2 kg-m, 9.0 Ib-ft)
11) Install brake drum. (Refer to steps 3) to 7) on WHEEL BEAR-
ING AND WHEEL STUD in this section.)
12) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to BLEEDING BRAKES in Section
5.)
13) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load two to three times so as to obtain proper
drum-to-shoe clearance.
14) Check to make sure that brake drum is free from dragging and
brake works properly.
Then remove vehicle from lift and perform brake test.
3E1-16 REAR SUSPENSION
09924–74510
Bearing installer handle
09942-15510
Sliding hammer
09943-17912
Brake drum remover
09913-76010
Rear wheel bearing
installer
09951-16030
Bearing installer (f51)
09951-16060
Bearing installer (f45)
REAR SUSPENSION 3E1-17
REQUIRED SERVICE MATERIALS
MATERIALS
RECOMMENDED
SUZUKI PRODUCT
USE
Brake fluid DOT3 Brake reservoir tank
Water tight sealant
SEALING COMPOUND 366E
(99000-31090)
Joint seam of rear axle and brake back plate
SPECIAL TOOLS

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