Japanese wild-card entrant Takao Suzuki took the first set from Switzerland's Federer 6-4 before Federer rebounded for a 7-5 win in the second set. The third set went to Federer only after he took the tiebreaker 7-3.
"It was a difficult match and I was afraid I might lose it," Federer said after the shaky win. "I got a bit of luck here and there in the third set which helped."
In other quarterfinals Friday, ninth-seeded Korean Hyung-Taik Lee upset second- seeded Spaniard Tommy Robredo 7-6 (7-3), 4-6, 6-1, and 10th-seeded Brit Tim Henman upended third-seeded Croat Mario Ancic 6-2, 6-2.
The tournament is scheduled to conclude Sunday.