Subaru 2001 Forester User manual

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair of

SUBARU vehicles.

This manual includes the procedures for

maintenance, disassembling, reassem-

bling, inspection and adjustment of com-

ponents and diagnostics for guidance of

experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping their

vehicle in optimum condition. When

replacement of parts during repair work is

needed, be sure to use SUBARU genu-

ine parts.

All information, illustration and specifica-

tions contained in this manual are based

on the latest product information avail-

able at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.

2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

G8050GE5

FRONT SUSPENSION FS

Page

1. General Description.....................................................................................2

2. Wheel Alignment .........................................................................................6

3. Front Transverse Link ...............................................................................14

4. Front Ball Joint..........................................................................................17

5. Front Strut .................................................................................................18

6. Front Stabilizer..........................................................................................22

7. Front Crossmember ..................................................................................23

8. General Diagnostic Table..........................................................................24

1. General Description S202001

A: SPECIFICATIONS S202001E49

1. STABILIZER S202001E4901

Model Bar dia.

Front Rear

NON-TURBO 19 mm (0.75 in) 13 mm (0.51 in)

TURBO 20 mm (0.79 in) 15 mm (0.59 in)

2. WHEEL ALIGNMENT S202001E4902

Model NON-TURBO TURBO

Camber (tolerance: ±0°30′)−0°15′−0°20′

Caster (common difference: ±0°45′)−0°37′−0°57′

Toe-in 0±3mm(0±0.12 in)*

Each toe angle: ±0°09′

Kingpin angle 13°25′13°40′

Wheel arch height

[tolerance:

+12

−24

mm (

+0.47

−0.94

in) 432 mm (17.01 in) 422 mm (16.61 in)

*: When performing toe-in adjustment, align as close to 0 mm (0 in) as possible.

NOTE:

쐌Front and rear toe-ins and front camber can be

adjusted. If toe-in or camber tolerance exceeds

specifications, adjust toe-in and camber to the

middle value of specification.

쐌The other items indicated in the specification

table cannot be adjusted. If the other items

exceeds specifications, check suspension parts

and connections for deformities; replace with new

ones as required.

B4M2250B

(1) Front

A−B = Positive: Toe-in, Negative: Toe-out

α= Each toe angle

FS-2

GENERAL DESCRIPTION

Front Suspension

B: COMPONENT S202001A05

S4M0317B

(1) Front crossmember

(2) Bolt ASSY

(3) Housing

(4) Washer

(5) Stopper rubber (Rear)

(6) Rear bushing

(7) Stopper rubber (Front)

(8) Ball joint

(9) Transverse link

(10) Cotter pin

(11) Front bushing

(12) Stabilizer link

(13) Clamp (Non-Turbo model)

(14) Bushing (Non-Turbo model)

(15) Stabilizer

(16) Jack-up plate

(17) Dust seal

(18) Strut mount

(19) Spacer

(20) Upper spring seat

(21) Rubber seat

(22) Dust cover

(23) Helper

(24) Coil spring

(25) Damper strut

(26) Adjusting bolt

(27) Castle nut

(28) Self-locking nut

(29) Adapter front crossmember

(30) Clip

(31) Clamp (Turbo model)

(32) Bushing (Turbo model)

Tightening torque: N·m (kgf-m, ft-lb)

T1: 20 (2.0, 14.5)

T2: 25 (2.5, 18.1)

T3: 30 (3.1, 22)

T4: 40 (4.1, 30)

T5: 45 (4.6, 33)

T6: 50 (5.1, 37)

T7: 55 (5.6, 41)

T8: 100 (10.2, 74)

T9: 175 (17.8, 129)

T10: 190 (19.4, 140)

T11: 245 (25.0, 181)

FS-3

GENERAL DESCRIPTION Front Suspension

C: CAUTION S202001A03

쐌Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-

tion.

쐌Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

쐌Keep the disassembled parts in order and pro-

tect them from dust or dirt.

쐌Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary

removal, installation, disassembly, and replace-

ment.

쐌Use SUBARU genuine grease etc. or the

equivalent. Do not mix grease etc. with that of

another grade or from other manufacturers.

쐌Be sure to tighten fasteners including bolts and

nuts to the specified torque.

쐌Place shop jacks or safety stands at the speci-

fied points.

쐌Apply grease onto sliding or revolution surfaces

before installation.

쐌Before installing O-rings or snap rings, apply

sufficient amount of grease to avoid damage and

deformation.

쐌Before securing a part on a vise, place cushion-

ing material such as wood blocks, aluminum plate,

or shop cloth between the part and the vise.

FS-4

GENERAL DESCRIPTION

Front Suspension

D: PREPARATION TOOL S202001A17

1. SPECIAL TOOLS S202001A1701

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

B4M2378A

927380002 ADAPTER Used as an adapter for camber & caster gauge

when measuring camber and caster.

(1) 28199AC000 PLATE

(2) 28199AC010 BOLT

B4M2385

927680000 INSTALLER &

REMOVER SET Used for replacing transverse link bushing.

B4M2384

927760000 STRUT MOUNT

SOCKET Used for disassembling and assembling strut

and shock mount.

2. GENERAL PURPOSE TOOLS S202001A1702

TOOL NAME REMARKS

Alignment Gauge Used for wheel alignment measurement.

Turning Radius Gauge Used for wheel alignment measurement.

Toe-in Gauge Used for toe-in measurement.

Dial Gauge Used for damper strut measurement.

FS-5

GENERAL DESCRIPTION Front Suspension

2. Wheel Alignment S202116

A: INSPECTION S202116A10

Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure:

B4M1088A

FS-6

WHEEL ALIGNMENT

Front Suspension

1. WHEEL ARCH HEIGHT S202116A1006

1) Adjust tire pressure to specifications.

2) Set vehicle under “curb weight”conditions. (Empty luggage compartment, install spare tire, jack, ser-

vice tools, and top up fuel tank.)

3) Set steering wheel in a wheel-forward position.

4) Suspend thread from wheel arch (point “A”in figure below) to determine a point directly above center

of spindle.

5) Measure distance between measuring point “A”and center of spindle.

S4M0086B

(1) Wheel arch height

(2) Front fender

(3) Outer rear quarter

(4) Front wheel arch height

(5) Rear wheel arch height

(6) Cross-section of arch

(7) Measuring point

(8) End of spindle

Model Specified wheel arch height

Front Rear

Non-Turbo 432

+12

−24

mm (17.01

+0.47

−0.94

in) 435

+12

−24

mm (17.13

+0.47

−0.94

in)

Turbo 422

+12

−24

mm (16.61

+0.47

−0.94

in) 425

+12

−24

mm (16.73

+0.47

−0.94

in)

FS-7

WHEEL ALIGNMENT Front Suspension

2. CAMBER S202116A1002

쐌Inspection

1) Place front wheel on turning radius gauge.

Make sure ground contacting surfaces of front and

rear wheels are set at the same height.

2) Set ST into the center of the wheel, and then

install the wheel alignment gauge.

ST 927380002 ADAPTER

S4M0087C

(1) Alignment gauge

(2) Turning radius gauge

NOTE:

Refer to the “SPECIFICATIONS”for the camber

values.

Front

<Ref. to FS-2, SPECIFICATIONS, General

Description.>

Rear

<Ref. to RS-2, SPECIFICATIONS, General

Description.>

쐌Front Camber Adjustment

1) Loosen two self-locking nuts located at lower

front portion of strut.

CAUTION:

쐌When adjusting bolt needs to be loosened or

tightened, hold its head with a wrench and turn

self-locking nut.

쐌Discard loosened self-locking nut and

replace with a new one.

쐌When performing toe-in adjustment, align as

close to 0 mm (0 in) as possible.

2) Turn camber adjusting bolt so that camber is

set at the specification.

NOTE:

Moving the adjusting bolt by one scale graduation

changes camber by approximately 0°10′.

S4M0300B

(1) Strut

(2) Adjusting bolt

(3) Housing

(4) Outer

(5) Inner

(6) Camber is increased.

(7) Camber is decreased.

FS-8

WHEEL ALIGNMENT

Front Suspension

Left side Right side

Camber is increased.

B4M0190

Rotate counterclock-

wise.

B4M0350

Rotate clockwise.

Camber is decreased.

B4M0350

Rotate clockwise.

B4M0190

Rotate counterclock-

wise.

3) Tighten the two self-locking nuts.

Tightening torque:

175 N·m (17.8 kgf-m, 129 ft-lb)

3. CASTER S202116A1003

쐌Inspection

1) Place front wheel on turning radius gauge.

Make sure ground contacting surfaces of front and

rear wheels are set at the same height.

2) Set ST into the center of the wheel, and then

install the wheel alignment gauge.

ST 927380002 ADAPTER

S4M0087C

(1) Alignment gauge

(2) Turning radius gauge

NOTE:

Refer to the “SPECIFICATIONS”for the caster val-

ues. <Ref. to FS-2 SPECIFICATIONS, General

Description.>

4. FRONT WHEEL TOE-IN S202116A1004

쐌Inspection

1) Using a toe gauge, measure front wheel toe-in.

Toe-in:

0±3mm(0±0.12 in)

2) Mark rear sides of left and right tires at height

corresponding to center of spindles and measure

distance “A”between marks.

3) Move vehicle forward so that marks line up with

front sides at height corresponding to center of

spindles.

4) Measure distance “B”between left and right

marks. Toe-in can then be obtained by the follow-

ing equation:

A−B = Toe-in

H4M1279B

FS-9

WHEEL ALIGNMENT Front Suspension

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