Front Suspension Frame, Stabilizer Bar and/or Bushing 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 kgf-m, 36.5 lbf-ft) 

   Fig 1: Identifying Alignment Of Stopper Ring With Stabilizer Bushing

   Courtesy of SUZUKI OF AMERICA CORP.
4. Install P/S gear box assembly (1) and front differential assembly (2) (if equipped) referring to Refer to P/S GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION and FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING .
   Fig 2: Installing 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.
   NOTE: 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 Lug In Suspension Frame, Engine Front Body Side Mounting Bolts

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6. Tighten suspension frame mounting bolts (1) and engine front body side mounting nuts (2) to specified torque.
   NOTE: 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 Bolts And Engine Front Body Side Mounting 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: Identifying Rope And Radiator

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9. Install engine hood. Refer to HOOD REMOVAL AND INSTALLATION .
10. Install front propeller shaft (if equipped). Refer to 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 kgf-m, 8.5 lbf-ft) 

    Fig 7: Identifying Pipe Bracket Bolts, Low Pressure Return Hose And 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 kgf-m, 25.5 lbf-ft) 

    Fig 8: Identifying Union Gear Box Bolt

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13. Connect steering lower shaft from pinion shaft steering. Refer to P/S GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION .
14. For headlight auto leveling model, attach front fender lining clip (1).
    Fig 9: Identifying 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: Identifying Front Height Sensor Connector And Clip

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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 kgf-m, 43.5 lbf-ft) 

    Fig 11: Tightening Stabilizer Joint Nut

    Courtesy of SUZUKI OF AMERICA CORP.
17. Install right side and left side front drive shaft assembly (if equipped). Refer to FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
18. Install suspension control arm. Refer to Suspension Control Arm Removal and Installation .
19. Install engine under cover and engine splash cover.
20. Install front wheels and tighten wheel nuts to specified torque. Refer to WHEEL (WITH TIRE) REMOVAL AND INSTALLATION .
21. After installation, be sure to fill specified power steering fluid and bleed air. Refer to P/S SYSTEM AIR BLEEDING PROCEDURE .
22. Check front wheel alignment adjust it as necessary. Refer to Front Wheel Alignment Inspection and Adjustment .