Suzuki Aerio, Verona 2002-06

Lower Control Arms

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Bushing Replacement



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the lower control arm.
  4.  
  5. Cut the flange from the front bushing.
  6.  
  7. Use a hydraulic press to remove the front bushing.

    Click image to see an enlarged view

    Fig. Cut the flange from the front bushing, then using a suitable hydraulic press; remove the rear lower control arm bushing

  8.  

To install:

  1. Apply a solution of soapy water to the outer diameter of the front bushing, this will aid in installation.
  2.  
  3. Press the front bushing into its bore using a hydraulic press until the bushing is equal on the right and left of the arm as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. The front bushing should be positioned equally as shown after being pressed into position

  4.  

  1. Remove the control arm.
  2.  
  3. Remove the control arm rear bushing using a press, the removal plate KM-307-B, and a drift.
  4.  
  5. Remove the control arm front bushing using a press, the remover/installer KM-508-A and the removal plate KM-307-B.
  6.  

To install:

  1. Coat the control arm rear shaft with a multipurpose lubricant.
  2.  
  3. Press the control arm front bushing into the control arm using a press, the remover/installer KM-508-A and the removal plate KM-307-B. Center the bushing.
  4.  
  5. Coat the outside of the control arm front bushing and the inside of the control arm with a multipurpose lubricant.
  6.  
  7. Press the control arm front bushing into the control arm using a press, the remover/installer KM-508-A, and the removal plate KM-307-B. Center the bushing.
  8.  
  9. Install the control arm.
  10.  

Removal & Installation



  1. Remove the wheel.
  2.  
  3. Disconnect the ball joint pinion from the control arm.
  4.  
  5. Install cap nut 7062-1 on the ball joint pinion.
  6.  
  7. Tighten the nut against the control arm.
  8.  
  9. Then turn back one turn to form a gap between the cap nut and the control arm.
  10.  
  11. Position the extractor on the control arm. Detach the ball joint from the control arm.
  12.  
  13. Pull down the control arms using a tension strap.
  14.  
  15. Release the spring strut from the control arm.
    WARNING
    Ensure that the tension strap is correctly secured in the control arms.

  16.  
  17. Remove the bolt for the halfshaft. Use a prybar as a counterhold on the brake disc.
  18.  
  19. Remove the halfshaft from the hub. Knock the halfshaft out using a brass drift.
  20.  
  21. Push the spring strut one side. Remove the tensioning strap between the control arms.
    WARNING
    Ensure that the tensioning strap does not get trapped when releasing.

  22.  
  23. Remove the splash guard under the engine.
  24.  
  25. Applies to the right-hand side only: Remove the hose for the EVAP canister and the fuel line for the engine block heater (where applicable) from their mountings. Move the hose and fuel line to one side.
  26.  
  27. Only applies to cars with 4T65EV transaxles when removing the left-hand control arm: Remove the bolt for the front engine pad. Lift the engine approximately 1 / 3 inch (10mm) using a mobile jack to remove the rear bolt on the front mounting for the control arm.
    NOTE
    Position the mobile jack so that it is raised towards the front right mounting bolt for the lower torque rod bracket.

  28.  

Applies to all models:

  1. Remove:

    The two bolts
     
    The bolt and nut
     
    The control arm

    Click image to see an enlarged view

    Fig. Removing the lower control arm

     

  2.  

To install:

  1. Install:
    NOTE
    Use new bolts.



    The control arm. Torque the front bolt to 48 ft. lbs. (65 Nm) plus 120°. Torque the rear bolt/nut to 78 ft. lbs. (105 Nm) plus 120°
     

  2.  
  3. Only applies to cars with 4T65EV transaxles when removing the left-hand control arm: Lower the engine. Install the bolt for the front engine pad. M10.
  4.  
  5. Applies to the right-hand side only: Install the hose for the EVAP canister and the fuel line for the engine block heater (if applicable) in their mountings.
  6.  

Applies to all models:

  1. Install the tensioning strap between the control arms and tighten.
  2.  
  3. Insert the halfshaft in the hub.
  4.  
  5. Position the spring strut over the ball joint. Release the tensioning strap so that the control arm meets the ball joint.
    WARNING
    Ensure that the tensioning strap does not get trapped when releasing.

  6.  
  7. Install the halfshaft in the hub. Install a new bolt. Use a prybar as a counterhold.
  8.  
  9. Install the upper ball joint nut. Tighten to 59 ft. lbs. (80 Nm).
  10.  
  11. Install the splashguard under the engine.
  12.  
  13. Install the wheels.
  14.  

The lower control arm and ball joint are a complete unit that will not separate.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Front wheels
     
    Suspension control arm ball joint bolt and nut
     
    Suspension control arm bolts
     
    Suspension control arm
     

  4.  

To install:

  1. Install suspension control arm as shown but tighten suspension control arm bolts only temporarily.
  2.  
  3. Install suspension control arm ball joint to steering knuckle. Align ball stud groove with steering knuckle bolt hole. Then install ball joint bolt from the front direction. Tighten suspension arm ball joint nut to 43.5 ft. lbs. (60 Nm).
  4.  
  5. Lower hoist and vehicle in non-loaded condition, tighten control arm mounting bolts to 65 ft. lbs. (90 Nm).
  6.  
  7. Check front wheel alignment.
  8.  

The lower control arm and ball joint are a complete unit that will not separate.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the front of the vehicle.
  6.  
  7. Remove or disconnect the following:

    Front wheels
     
    Control arm joint bolt
     
    Ball joint from the knuckle assembly
     
    Control arm bracket bolts
     
    Stabilizer link
     
    Control arm bolt and control arm assembly
     
    Control arm bracket from the control arm by removing the nut.
     

  8.  

To install:


CAUTION
The weight of the vehicle must be supported by the control arms before the stabilizer link-to-control arm nuts or the stabilizer shaft-to-stabilizer link nuts are tightened. This can be done by lowering the vehicle onto jack stands under the control arms have been installed.

  1. Install or connect the following:

    Control arm bracket nut and tighten to 81 ft. lbs. (110 Nm).
     
    Control arm bracket bolts and control arm bolt. Tighten the control arm bracket bolts to 66 ft. lbs. (90 Nm) and control arm bolt to 133 ft. lbs. (180 Nm).
     
    Install the stabilizer link.
     
    Install the control arm joint bolt and tighten to 81 ft. lbs. (110 Nm).
     

  2.  
  3. Install the wheels.
  4.  
  5. Check the front wheel alignment.
  6.  

 
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