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

쐌Adjustment
1) Loosen the left and right side steering tie-rods
lock nuts.
2) Turn the left and right tie rods equal amounts
until the toe-in is at the specification.
Both the left and right tie-rods are right-hand
threaded. To increase toe-in, turn both tie-rods
clockwise equal amounts (as viewed from the
inside of the vehicle).
S4M0348A
(1) Lock nut
3) Tighten tie-rod lock nut.
Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
CAUTION:
Correct tie-rod boot, if it is twisted.
NOTE:
Check the left and right wheel steering angle is
within specifications.
5. REAR WHEEL TOE-IN S202116A1007
쐌Inspection
1) Using a toe-in gauge, measure rear wheel toe-
in.
Toe-in: 2±3 mm (0.08±0.12 in)
2) Mark rear sides of left and right tires at height
corresponding to center of spindles and measure
distance “B”between marks.
3) Move vehicle forward so that marks line up with
front sides at height corresponding to center of
spindles.
4) Measure distance “A”between left and right
marks. Toe-in can then be obtained by the follow-
ing equation:
B−A = Toe-in
M4A0059
쐌Adjustment
1) Loosen self-locking nut on inner side of rear
lateral link.
CAUTION:
쐌When loosening or tightening adjusting bolt,
hold bolt head 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.
S4M0349A
(1) Adjusting scale
(2) Rear lateral link
2) Turn adjusting bolt head until toe-in is at the
specification.
NOTE:
When left and right wheels are adjusted for toe-in
at the same time, the movement of one scale
graduation changes toe-in by approximately 3 mm
(0.12 in).
FS-10
WHEEL ALIGNMENT
Front Suspension

Left side Right side
Toe-in is
increased.
B4M0192
Rotate clockwise.
B4M0352
Rotate counter-
clockwise.
Toe-in is
decreased.
B4M0352
Rotate counter-
clockwise.
B4M0192
Rotate clockwise.
3) Tighten self-locking nut.
Tightening torque:
100 N·m (10.2 kgf-m, 74 ft-lb)
6. THRUST ANGLE S202116A1008
쐌Inspection
1) Position vehicle on a level surface.
2) Move vehicle 3 to 4 meters directly forward.
3) Determine locus of both front and rear axles.
4) Measure distance “L”between center line of
loci of the axles.
Thrust angle:
Less than 20 ′when “L”is equal to or
less than 15 mm (0.59 in).
S4M0350B
(1) Center line of loci (front axle)
(2) Center line of loci (rear axle)
FS-11
WHEEL ALIGNMENT Front Suspension

쐌Adjustment
1) Make thrust angle adjustments by turning toe-in
adjusting bolts of rear suspension equally in the
same direction.
2) When one rear wheel is adjusted in a toe-in
direction, adjust the other rear wheel equally in
toe-out direction, in order to make thrust angle
adjustment.
3) When left and right adjusting bolts are turned
incrementally by one graduation in the same
direction, the thrust angle will change approxi-
mately 10′[“L”is almost equal to 7.5 mm (0.295
in)].
Thrust angle:
0°±20 ′
S4M0350B
(1) Center line of loci (front axle)
(2) Center line of loci (rear axle)
NOTE:
Thrust angle refers to a mean value of left and right
rear wheel toe angles in relation to vehicle body
center line. Vehicle is driven straight in the thrust
angle direction while swinging in the oblique direc-
tion depending on the degree of the mean thrust
angle.
B4M0193B
(1) Front
(2) Thrust angle
(3) Body center line
Thrust angle:r=(α−β)/2
α: Right rear wheel toe-in angle
β: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitute for αand βin the equation.
B4M0194B
(1) Front
(2) Body center line
FS-12
WHEEL ALIGNMENT
Front Suspension

7. STEERING ANGLE S202116A1005
쐌Inspection
1) Place vehicle on a turning radius gauge.
2) While depressing brake pedal, turn steering
wheel fully to the left and right. With steering wheel
held at each fully turned position, measure both the
inner and outer wheel steering angle.
Steering angle:
Inner wheel
34.4°±1.5°
Outer wheel
30.2°±1.5°
쐌Adjustment
Turn tie-rod to adjust steering angle of both inner
and outer wheels.
CAUTION:
쐌Check toe-in.
쐌Correct boot if it is twisted.
S4M0348A
(1) Lock nut
FS-13
WHEEL ALIGNMENT Front Suspension

3. Front Transverse Link S202113
A: REMOVAL S202113A18
1) Set the vehicle on the lift.
2) Disconnect ground terminal from the battery.
3) Lift-up the vehicle and remove the wheel.
4) Disconnect stabilizer link from transverse link.
5) Remove bolt securing ball joint of transverse
link to housing.
S4M0090
6) Remove nut (do not remove bolt.) securing
transverse link to crossmember.
7) Remove two bolts securing bushing bracket of
transverse link to vehicle body at rear bushing
location.
S4M0091
8) Extract ball joint from housing.
9) Remove bolt securing transverse link to cross-
member and extract transverse link from cross-
member.
S4M0092
B: INSTALLATION S202113A11
1) Temporarily tighten the two bolts used to secure
rear bushing of the transverse link to body.
NOTE:
These bolts should be tightened to such an extent
that they can still move back and forth in the oblong
shaped hole in the bracket (which holds the bush-
ing).
2) Install bolts used to connect transverse link to
crossmember and temporarily tighten with nut.
CAUTION:
Discard loosened self-locking nut and replace
with a new one.
3) Insert ball joint into housing.
4) Connect stabilizer link to transverse link, and
temporarily tighten bolts.
CAUTION:
Discard loosened self-locking nut and replace
with a new one.
S4M0090
5) Tighten the following points in the order shown
below when wheels are in full contact with the
ground and vehicle is curb weight.
(1) Transverse link and stabilizer
Tightening torque:
30 N·m (3.1 kgf-m, 22 ft-lb)
(2) Transverse link and crossmember
Tightening torque:
100 N·m (10.2 kgf-m, 74 ft-lb)
(3) Transverse link rear bushing and body
Tightening torque:
245 N·m (25 kgf-m, 181 ft-lb)
FS-14
FRONT TRANSVERSE LINK
Front Suspension

NOTE:
쐌Move rear bushing back and forth until trans-
verse link-to-rear bushing clearance is established
(as indicated in figure.) before tightening.
쐌Check wheel alignment and adjust if necessary.
S4M0352A
(1) Rear bushing
C: DISASSEMBLY S202113A06
1. FRONT BUSHING S202113A0601
Using ST, press front bushing out of place.
ST 927680000 INSTALLER & REMOVER SET
G4M0494
2. REAR BUSHING S202113A0602
1) Scribe an aligning mark on transverse link and
rear bushing.
2) Loosen nut and remove rear bushing.
G4M0495
FS-15
FRONT TRANSVERSE LINK Front Suspension

D: ASSEMBLY S202113A02
1. FRONT BUSHING S202113A0201
To reassemble, reverse disassembly procedures.
CAUTION:
Install front bushing in correct direction, as
shown in figure.
S4M0351A
(1) Face bushing toward center of ball joint
(2) Ball joint
2. REAR BUSHING S202113A0202
1) Install rear bushing to transverse link and align
aligning marks scribed on the two.
2) Tighten self-locking nut.
CAUTION:
쐌Discard loosened self-locking nut and
replace with a new one.
쐌While holding rear bushing so as not to
change position of aligning marks, tighten self-
locking nut.
Tightening torque:
190 N·m (19.4 kgf-m, 140 ft-lb)
E: INSPECTION S202113A10
1) Check transverse link for wear, damage and
cracks, and correct or replace if defective.
2) Check bushings for cracks, fatigue or damage.
3) Check rear bushing for oil leaks.
FS-16
FRONT TRANSVERSE LINK
Front Suspension

4. Front Ball Joint S202114
A: REMOVAL S202114A18
1) Set the vehicle on the lift.
2) Disconnect ground terminal from the battery.
3) Lift-up the vehicle and remove the wheel.
4) Pull out the cotter pin from the ball stud, remove
the castle nut, and extract the ball stud from the
transverse link.
5) Remove the bolt securing the ball joint to the
housing.
G4M0499
6) Extract the ball joint from the housing.
B: INSTALLATION S202114A11
1) Install ball joint onto housing.
Torque (Bolt):
50 N·m (5.1 kgf-m, 37 ft-lb)
CAUTION:
Do not apply grease to tapered portion of ball
stud.
2) Connect ball joint to transverse link.
Torque (Castle nut):
40 N·m (4.1 kgf-m, 30 ft-lb)
3) Retighten castle nut further within 60°until a
slot in castle nut is aligned with the hole in ball stud
end, then insert new cotter pin and bend it around
castle nut.
4) Install front wheel.
C: INSPECTION S202114A10
1) Measure play of ball joint by the following pro-
cedures. Replace with a new one when the play
exceeds the specified value.
(1) With 690 N (70.4 kgf, 155 lb) loaded in the
direction shown in the figure, measure dimen-
sion 
1
.
G4M0500
(2) With 690 N (70.4 kgf, 155 lb) loaded in the
opposite direction shown in the figure, measure
dimension 
2
.
G4M0501
(3) Calculate plays from the following formula.
S=
2
−
1
(4) When plays are larger than the following
value, replace with a new one.
FRONT BALL JOINT
Specified play for replacement: S
Less than 0.3 mm (0.012 in)
2) When play is smaller than the specified value,
visually inspect the dust cover.
3) The ball joint and cover that have been
removed must be checked for wear, damage or
cracks, and any defective part must be replaced.
4) If the dust cover is damaged, replace with the
new ball joint.
FS-17
FRONT BALL JOINT Front Suspension

5. Front Strut S202115
A: REMOVAL S202115A18
1) Set the vehicle on the lift.
2) Disconnect ground terminal from the battery.
3) Lift-up the vehicle and remove the wheel.
4) Depress brake pedal and hold it down using a
wooden block etc.
5) Remove union bolts from caliper.
CAUTION:
Use brake hose cap to prevent brake fluid from
escaping.
S4M0093
6) Remove brake hose clamp and disconnect
brake hose from strut. Attach brake hose to body
using gum tape.
S4M0094C
(1) Clamp
7) Scribe an alignment mark on the camber
adjusting bolt which secures strut to housing.
8) Remove bolt securing the ABS sensor harness
on models equipped with ABS.
B4M1442C
(1) Sensor harness
9) Remove two bolts securing housing to strut.
CAUTION:
While holding head of adjusting bolt, loosen
self-locking nut.
10) Remove the three nuts securing strut mount to
body.
G4M0505
FS-18
FRONT STRUT
Front Suspension

B: INSTALLATION S202115A11
1) Install strut mount at upper side of strut to body
and tighten with nuts.
Tightening torque:
20 N·m (2.0 kgf-m, 14.5 ft-lb)
2) Install ABS sensor harness to strut. (ABS
equipped models)
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
3) Position aligning mark on camber adjustment
bolt with aligning mark on lower side of strut.
CAUTION:
쐌While holding head of adjusting bolt, tighten
self-locking nut.
쐌Be sure to use new self-locking nut.
Tightening torque:
175 N·m (17.8 kgf-m, 129 ft-lb)
4) Install brake hose at lower side of strut with
clamp.
5) Install union bolts which secure brake caliper to
brake hose.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S4M0093
CAUTION:
Be sure to bleed air from brake system.
6) Install wheels.
NOTE:
Check wheel alignment and adjust if necessary.
C: DISASSEMBLY S202115A06
1) Using a coil spring compressor, compress coil
spring.
S4M0095
2) Using ST, remove self-locking nut.
ST 927760000 STRUT MOUNT SOCKET
S4M0096A
3) Remove strut mount, upper spring seat and
rubber seat from strut.
4) Gradually decreasing compression force, and
remove coil spring.
5) Remove dust cover and helper spring.
FS-19
FRONT STRUT Front Suspension