Suzuki Aerio, Verona 2002-06

Strut (MacPherson Strut) Assembly

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Overhaul (Coil Spring Removal & Installation)



  1. With special tool (A) 09940-71431 placed to spring as shown, turn special tool bolts alternately until spring tension is released. Whether it is released or not can be known by whether strut turns lightly while strut spring is held stationary.

    Click image to see an enlarged view

    Fig. Releasing spring tension

  2.  
  3. While keeping spring compressed with special tool as shown, remove strut nut.

    (A): 09945-26010 17 mm
     
    (B): 09900-00411
     
    (C): 09900-00414 6 mm

    Click image to see an enlarged view

    Fig. Remove strut nut

     

  4.  
  5. Disassemble strut assembly.
  6.  

To install:

  1. Compress spring with special tool (A) until total length becomes about 290 mm (11.42 in.).

    Click image to see an enlarged view

    Fig. Compress spring with special tool

  2.  
  3. Install coil spring lower seat (2) and compressing coil spring, mate large-diameter spring end with stepped part of lower seat as shown.

    Click image to see an enlarged view

    Fig. Install spring lower seat and compress coil spring

  4.  
  5. Install bump stopper onto strut rod.
  6.  
  7. Install dust cover onto bump stopper.
  8.  
  9. Fit coil spring (rubber) seat (2) in coil spring upper seat (1), making sure that their depth matches all around. No part of rubber seat should stick out higher than upper seat.

    Click image to see an enlarged view

    Fig. Fit coil spring (rubber) seal in coil spring upper seat

  10.  
  11. Pull strut rod as far up as possible and use care not to allow it to retract into strut.
  12.  
  13. With -OUT- mark (3) on spring upper seat (1) and the center of strut bracket (2) aligned, place upper spring seat together with spring (rubber) seat on coil spring.

    Click image to see an enlarged view

    Fig. Place upper spring seat together with spring (rubber) seat on coil spring

  14.  
  15. Put strut support (2) on spring upper seat (3). Tighten strut nut (1) to 50.5 ft. lbs. (70 Nm).

    Click image to see an enlarged view

    Fig. Put strut support on spring upper seat

  16.  
  17. Loosen and remove special tool (A) installed in Step 1) from compressing coil spring. While loosening special tool, recheck that stepped part of spring seat and spring end are in place to each other as described in foregoing Step 2). Also, check to make sure that -OUT- mark on upper seat is matched with the center of strut bracket as described in Step 7).
  18.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    When servicing component parts of strut assembly, loosen strut upper nut a little before removing strut assembly. This will make service work easier. Note, however, nut must not be removed at this point.

  2.  
  3. Raise and safely support the front of the vehicle.
  4.  
  5. Remove or disconnect the following:

    Rear wheel
     
    Stabilizer joint from strut bracket
     
    E-ring securing brake hose
     
    ABS wheel speed sensor harness mounting bolt (if equipped)
     
    Strut bracket bolts and nuts. And then take brake hose off strut bracket using care not to deform brake pipe.
     

  6.  
  7. Strut support nuts. Hold strut by hand so that it will not fall off.

    Strut assembly
     

  8.  
  9. Using a spring compressor tool, turn special tool bolts alternately until spring tension is released. Whether it is released or not can be known by whether strut turns lightly while strut spring is held stationary.
    NOTE
    Use a commercially available spring compressor and follow the operation procedure described in the Instruction Manual supplied with that spring compressor.

  10.  
  11. While keeping spring compressed, remove strut nut.
  12.  
  13. Disassemble strut assembly.

    Click image to see an enlarged view

    Fig. Rear strut assembly mounting

  14.  

To install:

  1. Assemble the coil spring into the strut assembly as follows:


    1. Compress spring with special tool until total length becomes about 11.42 inches (290mm).
    2.  
    3. Install coil spring lower seat and compressing coil spring, and mate spring end with stepped part of lower seat.
    4.  
    5. Install bump stopper and dust cover onto strut rod.
    6.  
    7. Pull strut rod as far up as possible and use care not to allow it to retract into strut.
    8.  
    9. Fit coil spring (rubber) seat in coil spring upper seat, making sure that their depth matches all around. No part of rubber seat should stick out higher than upper seat.
    10.  
    11. With -OUT- mark on spring upper seat and the center of strut bracket aligned, place upper spring seat together with spring (rubber) seat on coil spring. Put strut support on spring upper seat. Tighten strut nut to 50.5 ft. lbs. (70 Nm).
    12.  
    13. Loosen and remove special tool from compressing coil spring.
    14.  
    15. While loosening spring compressor tool, recheck that stepped part of spring seat and spring end are in place to each other.
    16.  
    17. Also, check to make sure that -OUT- mark on upper seat is matched with the center of strut bracket.
    18.  

  2.  
  3. Install or connect the following:
    NOTE
    Do not twist brake hose when installing it. Install E-ring as far as it fits to bracket.



    Strut assembly. Install the bracket bolts from the front direction and tighten the strut bracket nuts to 65 ft. lbs. (90 Nm). Tighten the strut support nuts to 20.5 ft. lbs. (28 Nm).
     
    E-ring securing brake hose
     



    Stabilizer joint to strut bracket. Tighten the stabilizer joint nut to 36.5 ft. lbs. (50 Nm).
     
    ABS wheel speed sensor harness, if equipped
     
    Wheels
     

  4.  
  5. Lower the vehicle.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    When servicing component parts of strut assembly, loosen strut upper nut a little before removing strut assembly. This will make service work easier. Note, however, nut must not be removed at this point.

  2.  
  3. Raise and safely support the front of the vehicle.
  4.  
  5. Remove or disconnect the following:

    Rear wheel
     
    Rear strut lower nut-to-knuckle
     
    Rear seat and rear strut upper nut-to-body.
     
    Rear strut assembly from the vehicle
     

  6.  
  7. Mount the rear strut assembly into the spring compressor KM-329-A. Ensure that the hooks are properly seated.
  8.  
  9. Compress the spring.
  10.  
  11. Remove the lock nut from the strut dampener rod.
  12.  
  13. Release the coil spring from the compressor and remove the rear strut mount, spring upper insulator, dust cover, hollow bumper, coil spring and rear spring lower insulator.
  14.  

To install:

  1. Install the rear spring lower insulator, coil spring, hollow bumper, dust cover, spring upper insulator and rear strut mount onto the rear strut assembly.
  2.  
  3. Compress the spring.
  4.  
  5. Install the lock nut to the strut damper rod.
  6.  
  7. Release the rear strut assembly from the spring compressor KM-329-A.
  8.  
  9. Install the rear strut with upper nut-to-body and rear seat. Tighten the rear strut upper nuts-to-body to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the rear strut with lower nut-to-knuckle and tighten the rear strut lower nuts-to-knuckle to 66 ft. lbs. (90 Nm).
  12.  
  13. Install the rear wheels.
  14.  
  15. Lower the vehicle.
  16.  

 
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