Get Rear Suspension (Coil Spring Type) -> On-Vehicle Service Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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

Rear Suspension (Coil Spring Type) -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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