Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation: Installation

Reference: FRONT SUSPENSION FRAME CHECK 

1. When installing stabilizer, loosely assemble all components while insuring that stabilizer is centered, side-to-side.
2. Install stabilizer bar (1), stabilizer bushing (2) and stabilizer mounting bracket (3) to suspension frame.
   NOTE:

   • For correct installation of stabilizer bar, side-to-side, be sure that stopper ring (5) on stabilizer bar aligns with stabilizer bushing, both right and left, as shown in figure.
   • Install stabilizer bushing so that a cut (6) becomes forward.
3. Tighten stabilizer bar mounting bracket bolts (4) to specified torque.

   Tightening torque 

   Stabilizer bar mounting bracket bolt (a): 50 N.m (5.0 kg-m, 36.5 lbf-ft) 

   Fig 1: Identifying Stabilizer Bar Mounting Bracket Bolt

   Courtesy of SUZUKI OF AMERICA CORP.
4. Install P/S gear box assembly (1) and front differential assembly (2) (if equipped) referring to P/S GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION and FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING .
   Fig 2: Identifying P/S Gear Box Assembly And Front Differential Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
5. Install suspension frame.
   WARNING: If the front suspension frame is not stably supported on a transmission jack or other supporting equipment during its installation, the frame could drop and cause personal injury. Make sure that the weight of the front suspension frame is supported at the frame's center and that the frame is well-balanced on the support.
   CAUTION: Lug (2) in suspension frame (1) must be mated to the corresponding hole in body. And also engine front body side mounting bolts (3) must be mated to the corresponding holes (4) in suspension frame.
   Fig 3: Identifying Suspension Frame And Engine Front Body Side Mounting Bolts

   Courtesy of SUZUKI OF AMERICA CORP.
6. Tighten suspension frame mounting bolts (1) and engine front body side mounting nuts (2) to specified torque.
   CAUTION: The front suspension frame mounting bolts are pre-coated with friction stabilizer. If these bolts are reused, they may work loose. Be sure to replace the front suspension frame mounting bolts with new ones whenever they are removed.

   Tightening torque 

   Suspension frame mounting bolt (a): 128 N.m (13.1 kgf-m, 94.5 lbf-ft) 

   Engine front body side mounting nut (b): 55 N.m (5.5 kgf-m, 40.0 lbf-ft) 

   Fig 4: Identifying Suspension Frame Mounting Bolt And Nuts

   Courtesy of SUZUKI OF AMERICA CORP.
7. Install engine splash cover (2) from front suspension frame (1) (if equipped).
   Fig 5: Identifying Engine Splash Cover And Front Suspension Frame

   Courtesy of SUZUKI OF AMERICA CORP.
8. Remove chain hoist from engine and the rope (1) from the radiator (2).
   Fig 6: Removing Chain Hoist From Engine And Rope

   Courtesy of SUZUKI OF AMERICA CORP.
9. Install engine hood, see HOOD REMOVAL AND INSTALLATION .
10. Install front propeller shaft (if equipped), see PROPELLER SHAFT REMOVAL AND INSTALLATION .
11. Tighten pipe bracket bolts (1) to specified torque and then connect low pressure return hose (2) to low pressure return pipe (3).

    Tightening torque 

    Pipe bracket bolt: 11 N.m (1.1 kg-m, 8.5 lbf-ft) 

    Fig 7: Identifying Pipe Bracket Bolts, Low Pressure Return Hose And Low Pressure Return Pipe

    Courtesy of SUZUKI OF AMERICA CORP.
12. Tighten union gear box bolt (1) to specified torque.

    Tightening torque 

    Union gear box bolt (a): 35 N.m (3.5 kg-m, 25.5 lbf-ft) 

    Fig 8: Identifying Union Gear Box Bolt

    Courtesy of SUZUKI OF AMERICA CORP.
13. Connect steering lower shaft from pinion shaft steering, see P/S GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION .
14. For headlight auto leveling model, attach front fender lining clip (1).
    Fig 9: Attaching Front Fender Lining Clip

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15. For headlight auto leveling model, connect front height sensor connector (1) and then attach clip (2).
    Fig 10: Connecting Front Height Sensor Connector And Clip

    Courtesy of SUZUKI OF AMERICA CORP.
16. Install stabilizer joints (1), and tighten nuts to specified torque. When tightening, hold stud with hexagon wrench.

    Tightening torque 

    Stabilizer joint nut (a): 60 N.m (6.0 kg-m, 43.5 lbf-ft) 

    Fig 11: Identifying Stabilizer Joints

    Courtesy of SUZUKI OF AMERICA CORP.
17. Install right side and left side front drive shaft assembly (if equipped), see FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
18. Install suspension control arm, see SUSPENSION CONTROL ARM REMOVAL AND INSTALLATION .
19. Install engine under cover.
20. Install front wheels and tighten wheel nuts to specified torque, WHEEL (WITH TIRE) REMOVAL AND INSTALLATION .
21. After installation, be sure to fill specified power steering fluid and bleed air, P/S SYSTEM AIR BLEEDING PROCEDURE .
22. Check front wheel alignment adjust it as necessary, see FRONT WHEEL ALIGNMENT INSPECTION AND ADJUSTMENT .