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HYUNDAI GETZ 2006 to 2011 Workshop Service Repair Manual Digital Download

- Safety first
- Work on a flat level surface, parking brake on, engine off, ignition key removed.
- Use wheel chocks on wheels remaining on the ground to prevent roll.
- Wear safety glasses, gloves, and steel-toe footwear.
- Never rely on a jack alone — always support the car on jack stands rated for the vehicle weight.

- Overview (what the stabilizer / anti-roll bar system is and common failures)
- The stabilizer (sway) bar links left and right suspension to reduce body roll. Typical failures: worn/collapsed rubber bushings, loose or broken end links, seized bracket bolts, or a bent bar after impact.
- Symptoms requiring repair or replacement: clunking/knocking over bumps, excessive body roll, loose steering feel, visible cracked/deteriorated bushings or play in end links.

- Essential tools you need and how to use each (detailed)
- Hydraulic trolley jack (1–2 tonne capacity)
- Description: low-profile floor jack used to lift the car.
- How to use: position under manufacturer jacking point (see owner’s manual), pump handle to raise, don’t work under car supported only by jack.
- Why required: raises vehicle so you can remove wheel and access the stabilizer bar area.
- Quality rated jack stands (pair)
- Description: adjustable-support stands that hold the car at a safe height.
- How to use: after raising vehicle with jack, lower the car onto stands placed under solid points (subframe or pinch weld), ensure both stands are same height and car is stable.
- Why required: provides safe stable support while working under car.
- Wheel chocks (pair)
- Description: rubber or plastic wedges.
- How to use: place behind rear wheels (or front wheels if rear is lifted).
- Why required: prevents vehicle roll.
- Lug wrench / breaker bar for wheel nuts
- Description: long-handled cross or socket wrench for wheel studs.
- How to use: loosen wheel nuts slightly while car is on the ground; remove after car is raised.
- Why required: wheel removal.
- Socket set (metric) with ratchet and extensions (common sizes: 10, 12, 14, 17, 19 mm)
- Description: sockets and ratchet for removing bolts/nuts.
- How to use: choose correct socket size, fit ratchet and turn counterclockwise to loosen.
- Why required: remove end links, bracket bolts, wheel nuts.
- Combination spanners (open-end/box-end, metric set)
- Description: hand wrenches for nuts/bolts where sockets won’t fit.
- How to use: hold bolt head with spanner while turning nut with socket or another spanner.
- Why required: many sway-bar link assemblies require holding one side while turning the other.
- Torque wrench (click type, appropriate range e.g., 10–150 Nm)
- Description: adjustable wrench calibrated to apply a specific torque.
- How to use: set required torque, tighten until it clicks, avoid over-torquing.
- Why required: fasteners must be tightened to manufacturer torque to avoid failure or thread damage.
- Penetrating oil (e.g., WD-40 / PB Blaster)
- Description: liquid that loosens rusted/seized bolts.
- How to use: spray on bolts, wait 10–15 minutes, repeat if needed.
- Why required: many sway bar bolts are corroded; penetrating oil reduces breakage risk.
- Breaker bar (long non-ratcheting bar)
- Description: long lever for extra torque to break loose tight bolts.
- How to use: attach socket, apply steady force; use feet/hips for leverage.
- Why required: to free seized nuts without rounding bolt heads.
- Hammer and punch / mallet
- Description: steel hammer or rubber mallet and drift/punch.
- How to use: tap stuck sleeves, taps to free seized studs; rubber mallet avoids damage when needed.
- Why required: sometimes sway-bar or link parts seize and need persuasion.
- Pry bar / large screwdriver
- Description: metal lever to pry components.
- How to use: carefully pry the sway bar or brackets away to free bushings.
- Why required: to get old bushings out or move bar for fitting new parts.
- Wire brush
- Description: stiff bristled brush for rust removal.
- How to use: clean mating surfaces before installing new parts.
- Why required: ensures good fit and prevents future corrosion seizing.
- Grease (lithium or silicone grease depending on bushing type) and small brush or syringe
- Description: lubricant to reduce squeaks and help bushing fit.
- How to use: apply as manufacturer indicates onto rubber/urethane bushings (polyurethane usually needs specific grease).
- Why required: reduces wear and noise; polyurethane bushings require special grease or they squeak.
- Anti-seize compound
- Description: paste applied to threads to prevent galling.
- How to use: light coat on bolts threads (unless manufacturer forbids).
- Why required: eases future removal and prevents thread corrosion.
- Impact wrench (electric or pneumatic) — optional
- Description: high-torque power wrench.
- How to use: use with correct sockets; be careful with over-torque and use torque wrench for final tightening.
- Why optional: speeds removal of stubborn bolts; not required but useful in workshop.
- Small torch (propane) — optional
- Description: heats stuck bolts to expand and free them.
- How to use: heat bolt carefully, apply penetrating oil, then try breaker bar.
- Why optional: last resort for severely seized bolts; use caution and avoid fuel lines or rubber.
- Replacement parts and consumables (described below)
- Description and how used explained in replacement section.

- Diagnostic and inspection (what to check before you start)
- Visually inspect bushings (rubber sleeves around bar where it attaches to chassis) for cracks, split, flattened shape or missing halves.
- Check end links (drop links) for play: with wheel raised, wiggle the link by hand — if you feel movement in joints or hear clicking, link is worn.
- Check bracket bolts for corrosion and check sway bar for bends or damage.
- If only bushings are damaged, you can replace bushings; if end links fail or are seized/bent, replace end links; if bar is bent or cracked, replace the whole bar.

- Parts you may need and why
- Stabilizer bar bushings (rubber or polyurethane)
- Why replace: rubber degrades and causes looseness and noise; polyurethane is stiffer and longer-lasting but may increase NVH (noise, vibration, harshness).
- How supplied: split or two-piece bushings that clamp around the bar with a bracket.
- Sway bar end links (drop links)
- Why replace: they have ball joints/bushings that wear; worn links cause clunks and reduced roll control.
- How supplied: complete assemblies with studs, nuts, and sometimes split pins.
- Bracket clamps and bolts (if corroded)
- Why replace: corroded brackets may not clamp securely or may break during removal.
- Full stabilizer bar (rare)
- Why replace: if bent, cracked or severely corroded. Replacing full bar is more work and may require removing additional suspension components.
- Bolts, nuts, washers (new hardware recommended)
- Why replace: if old hardware is corroded or stretched; always fit new locking nuts where specified.

- Step-by-step repair procedure (workshop-level, beginner friendly)
- Preparation
- Loosen front wheel lug nuts a couple of turns while the car is on the ground.
- Apply penetrating oil to the end link nuts and bracket bolts; let soak.
- Lift and secure car
- Jack car at correct jacking point, raise enough to remove wheel, place jack stands under solid support points, lower gently onto stands, and confirm stability.
- Remove wheel and set aside.
- Access and inspect
- Locate stabilizer bar, bushings (mounted to chassis with metal brackets) and end links (connect bar to strut or control arm).
- Inspect components and confirm which parts need replacement.
- Remove end link(s)
- Hold the inner stud head with a spanner and remove the nut on the outer side; if link is seized, use breaker bar or impact after penetrating oil.
- If the link has a centered hex or an Allen/torx nub to hold the stud, insert the required key to prevent rotation while undoing the nut.
- Remove the link; if stuck, tap with hammer on the stud from the back to free it or use a puller.
- Remove bushing brackets
- Unscrew the bolts holding the bracket to the chassis (usually two bolts each side).
- Remove bracket and take off the old bushing halves.
- If bracket bolts are seized, use penetrating oil, breaker bar or heat (careful).
- Remove old bushings
- Pry out old rubber bushings; wire brush mounting surfaces clean of rust and dirt.
- Inspect bar and recondition if possible
- Check the bar surface where bushings sit; clean and remove rust, flatten high spots.
- If bar is bent or cracked, replace the whole bar.
- Fit new bushings
- For split bushings, open and place around the bar at correct position (match original orientation).
- Lightly grease bushing inner surface if manufacturer allows (polyurethane needs specific grease).
- Refit bracket and loosely start bolts so you can align before torquing.
- Refit or replace end links
- Fit new or inspected end links to the strut/control arm and bar, install nuts and washers.
- Tighten nut until snug by hand first, then final torque with torque wrench to manufacturer spec.
- Final torque and checks
- Tighten bushing bracket bolts to manufacturer torque spec with torque wrench; if you don’t have specs, check a repair manual or use conservative values and get final check by a professional.
- Recheck all fasteners for tightness; use anti-seize on threads where appropriate before fitting new bolts.
- Reinstall wheel, lower car, torque wheel nuts
- Hand-tighten wheel nuts, lower vehicle off stands carefully, then torque wheel nuts to manufacturer spec in a star pattern.
- Road test
- Drive slowly and check for noises; recheck torque after 50–100 km.

- Specific usage tips for tricky operations
- Breaking seized bolts: apply penetrating oil, let soak overnight, then use breaker bar. If still seized, heat bolt with torch briefly and reapply penetrating oil.
- Removing stuck end link studs: use hammer blows to the nut (with the nut removed) on the stud to break corrosion, or use a tie-rod puller/puller tool.
- Aligning bushings: leave bracket bolts slightly loose while adjusting position, then torque to spec once everything sits naturally.
- Torque wrench use: set dial to desired Nm, tighten slowly until it clicks; store wrench at lowest setting after use.

- Torque and specification guidance
- Always consult a Hyundai Getz workshop manual for exact torque values.
- Typical approximate ranges (use only if manual not available and double-check later):
- Sway bar bracket bolts: ~25–45 Nm
- End link nuts: ~40–70 Nm (depends on link design)
- Wheel nuts: see wheel/tyre spec (often 100–130 Nm on many small cars)
- When in doubt, tighten to a firm feel and have a professional check final torque.

- When to replace which part (quick decision guide)
- Replace bushings only if rubber is split, flattened, or collapsed.
- Replace end links if ball joints have play, rubber boots are torn, or rods are bent.
- Replace bracket bolts if corroded or threads damaged.
- Replace entire bar if bent, cracked, or severely corroded.

- Extra tools you might need in a workshop scenario and why
- Service hoist (2-post or 4-post lift): faster and safer access to underside and wheels; avoids repeated jacking.
- Impact gun with air compressor: speeds removal of wheel and seized bolts.
- Pullers (ball joint or tie-rod puller): effective for separating pressed joints without damage.
- Heat source/oxy-propane: for extremely seized bolts; use only with training.
- Torque angle gauge and service manual: for precise tightening sequences and specs.

- Final checks and maintenance after repair
- Recheck all fasteners after a short test drive.
- Listen for new noises; if you hear squeaks from new polyurethane bushings, apply correct grease.
- Keep records of replaced parts for future service.

- Consumables & parts to buy before starting
- Pair of sway bar bushings (or full kit)
- Pair of sway bar end links (front pair if doing both sides)
- New bolts/nuts if original hardware is corroded
- Penetrating oil, anti-seize, grease
- Shop rags and cleaning brush

- Quick safety reminders (no excuses)
- Never work under a car supported only by a jack.
- If a bolt is beyond your skill or requires dangerous heat near fuel/lines, stop and have a professional finish it.
- If uncertain about torque values or alignment after repair, have a workshop check your work.

- Estimated time for a beginner (workshop)
- Approximately 1.5–3 hours per axle if you have all tools and parts, longer if bolts are seized.

- Signs you should not attempt this yourself
- Severe rust fused components, bent bar, or inaccessible bolts requiring welding/advanced tools — get a professional.

- Useful spare parts to keep for a Hyundai Getz
- Front sway bar end links (pair), bush kit (pair), bracket bolts.

- Final note
- Follow the steps, use the correct tools as described, and replace failing parts rather than forcing worn components to stay — that ensures safety and correct handling.
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