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