How to Replace Strut Assembly 02-06 Suzuki XL-7

Difficulty: Advanced · About 75 min · Suzuki Xl-7

Replace the front strut assembly, including the air intake box above it, on a 2002-2006 Suzuki XL-7.

Steps

1. Remove the wheel

   Pry off the center cap, loosen the lugs with the car on the ground, then raise and support it and pull the wheel.

2. Move the air intake box aside

   Disconnect the mass airflow and intake temperature sensors, remove the box's three 10mm bolts, loosen its two hose clamps, then lift it out.

3. Remove the old strut

   Hold the top washer with a pipe wrench while removing its 19mm nut (a length of pipe adds leverage), unbolt the brake line's 10mm bolt and pry off its retaining clip, remove the strut's two 17mm nuts and bolts from the knuckle (tapping them out with a hammer and punch if needed), then work the strut free.

4. Install the new strut

   Transfer the old sleeve and washer onto the new strut, feed it into place, push the knuckle on, insert and torque the two 17mm bolts to about 75-80 ft-lb, then reconnect the brake line and its clip and bolt.

5. Reinstall the wheel

   Torque the lug nuts to about 100 ft-lb in a crossing pattern, then refit the center cap.

6. Reinstall the air intake box

   Confirm the top gasket is seated, thread on the washer and 22mm nut by hand while holding it with the pipe wrench, torque it to about 80-90 ft-lb, lower the intake box into place, reconnect its hose and tighten the clamps, then reconnect both sensors and refit its three 10mm bolts.

Check your vehicle’s repair manual for exact specifications and fit.