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

POWER ASSISTED SYSTEM (POWER
STEERING) PS
Page
1. General Description.....................................................................................2
2. Steering Wheel..........................................................................................27
3. Universal Joint...........................................................................................28
4. Tilt Steering Column..................................................................................30
5. Steering Gearbox [LHD Model].................................................................33
6. Steering Gearbox [RHD Model]................................................................53
7. Pipe Assembly...........................................................................................78
8. Oil Pump....................................................................................................93
9. Reservoir Tank ........................................................................................100
10. Power Steering Fluid...............................................................................101
11. General Diagnostic Table........................................................................103

1. General Description S601001
A: SPECIFICATIONS S601001E49
Model LHD RHD
Steering wheel Free play mm (in) 17 (0.67)
Turning angle Inner tire & wheel 34.4°±1.5°
Outer tire & wheel 30.2°±1.5°
Steering shaft Clearance between steering
wheel and column cover mm (in) 3.0 (0.118)
Steering gearbox
(Power steering
system)
Sliding resistance N (kgf, lb) 304.0 (31.0, 68.4) or less
Rack
shaft play
in radial
direction
Right-turn
steering mm (in) 0.15 (0.0059) or less
Horizontal movement:
0.6 (0.024) or less
Vertical movement:
0.4 (0.016) or less
Left-turn
steering mm (in)
Horizontal movement:
0.3 (0.012) or less
Vertical movement:
0.15 (0.0059) or less
0.4 (0.016) or less
Input
shaft play
In radial
direction mm (in) 0.18 (0.0071) or less
In axial
direction mm (in) 0.1 (0.004) or less
Turning resistance N (kgf, lb) Within 30 mm (1.18 in) from rack center in straight ahead position: Less than 11.18 (1.14, 2.51)
Maximum allowable value: 12.7 (1.3, 2.9)
Oil pump
[Non-turbo model
(Power steering
system)]
Pulley
shaft Radial play mm (in) 0.4 (0.016) or less
Axial play mm (in) 0.9 (0.035) or less
Pulley Ditch deflection mm (in) 1.0 (0.039) or less
Resistance to
rotation N (kgf, lb) 9.22 (0.94, 2.07) or less
Regular pressure kPa (kg/cm
2
, psi) 981 (10, 142) or less
Relief pressure kPa (kg/cm
2
, psi) 7,355 (75, 1,067)
Oil pump
[Turbo model
(Power steering
system)]
Pulley
shaft Radial play mm (in) 0.4 (0.016) or less
Axial play mm (in) 0.6 (0.024) or less
Pulley Ditch deflection mm (in) 1.0 (0.039) or less
Resistance to
rotation N (kgf, lb) 9.22 (0.94, 2.07) or less
Regular pressure kPa (kg/cm
2
, psi) 981 (10, 142) or less
Relief pressure kPa (kg/cm
2
, psi) 9,807 (100, 1,422)
Steering wheel
effort
(Power steering
system)
At standstill with engine
idling on a concrete road N (kgf, lb) 29.4 (3.0, 6.6) or less
At standstill with engine
stalled on a concrete road N (kgf, lb) 294.2 (30, 66.2) or less
Recommended power steering fluid Manufacturer
ATF DEXRON IIE or III
B.P.
CALTEX
CASTROL
MOBIL
SHELL
TEXACO
PS-2
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

Model Non-turbo Turbo
Whole system
Minimum turning radius m (ft) 5.4 (17.7)
Steering angle (Inside-Outside) 34.4°±1.5°—30.2°±1.5°
Steering wheel diameter mm (in) With AIRBAG: 385 (15.16)
Without AIRBAG: 385 (15.16)
Overall gear ratio (Turns, lock to lock) LHD: 19.0 (3.4)
RHD: 16.7 (3.0)
Gearbox Type Rack and pinion, Integral Backlash 0 (Automatically adjustable)
Valve (Power steering system) Rotary valve
Pump
(Power steering
system)
Type Vane pump
Oil tank Installed on pump
Output cm
3
(cu in)/
rev. 7.2 —0.6 (0.439 —0.037) 9.6 —0.65 (0.586—0.040)
Relief pressure kPa (kg/cm
2
,
psi) 7,355 (75, 1,067) 7,846 (80, 1,138)
Hydraulic fluid control Drooping in response to increased engine revolutions
Hydraulic fluid (US qt, Imp
qt) 1,000 rpm: 7 (7.4, 6.2) 3,000 rpm: 5 (5.3, 4.4)
Range of revolution rpm 500 —7,500 500 —8,000
Revolving direction Clockwise
Working fluid
(Power steering
system)
Name ATF DEXRON IIE or III
Capacity
Oil tank (US qt, Imp
qt) 0.3 (0.3, 0.3)
Total (US qt, Imp
qt) 0.7 (0.7, 0.6)
CAUTION:
This table lists various clearances that must be
correctly adjusted to ensure normal vehicle
driving without interfering noise, or any other
faults.
Location Minimum allowance
(1) Crossmember —Pipe 5 mm (0.20 in)
(2) DOJ —Shaft or joint 14 mm (0.55 in)
(3) DOJ —Valve housing 11 mm (0.43 in)
(4) Pipe —Pipe 2 mm (0.08 in)
(5) Stabilizer —Pipe 5 mm (0.20 in)
(6) Exhaust pipe —Pipe 15 mm (0.59 in)
(7) Exhaust pipe —Gearbox bolt 15 mm (0.59 in)
(8) Side frame —Hose A and B 15 mm (0.59 in)
(9) Cruise control pump —Hose A and B 15 mm (0.59 in)
(10) Pipe portion of hose A —Pipe portion of hose B 1.5 mm (0.059 in)
(11) AT cooling hose —Joint (LHD model) 20 mm (0.79 in)
PS-3
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

쐌Non-turbo model
S4M0172A
쐌Turbo model
S4M0565A
PS-4
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

B: COMPONENT S601001A05
1. STEERING WHEEL AND COLUMN S601001A0501
쐌With Airbag Model
S4M0304B
(1) Bushing
(2) Steering shaft
(3) Knee protector
(4) Steering roll connector
(5) Column cover
(6) Steering wheel
(7) Airbag module Tightening torque: N·m (kgf-m, ft-lb)
T1: 1.2 (0.12, 0.9)
T2: 3.4 (0.35, 2.5)
T3: 25 (2.5, 18.1)
T4: 44 (4.5, 32.5)
PS-5
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

쐌Without Airbag Model
S4M0311A
(1) Bushing
(2) Steering shaft
(3) Knee protector
(4) Combination switch
(5) Column cover
(6) Steering wheel
(7) Pad ASSY Tightening torque: N·m (kgf-m, ft-lb)
T1: 1.2 (0.12, 0.9)
T2: 3.4 (0.35, 2.5)
T3: 25 (2.5, 18.1)
T4: 44 (4.5, 32.5)
PS-6
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

MEMO:
PS-7
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

2. POWER ASSISTED SYSTEM FOR NON-TURBO MODEL S601001A0504
쐌LHD Model
S4M0175E
PS-8
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

(1) Eye bolt
(2) Pipe C
(3) Gasket
(4) Clip
(5) Pipe D
(6) Clamp E
(7) O-ring
(8) Cap
(9) Strainer
(10) Upper shell
(11) Buffle
(12) Seal washer
(13) Lower shell
(14) Pulley
(15) Oil pump
(16) Bracket
(17) Belt tension nut
(18) Bushing
(19) Belt cover
(20) Pipe E
(21) Pipe F
(22) Clamp plate
(23) Universal joint
(24) Dust cover
(25) Valve housing
(26) Gasket
(27) Oil seal
(28) Special bearing
(29) Seal ring
(30) Pinion and valve ASSY
(31) Oil seal
(32) Back-up washer
(33) Ball bearing
(34) Snap ring
(35) Lock nut
(36) Adjusting screw
(37) Spring
(38) Sleeve
(39) Adapter
(40) Clamp
(41) Cotter pin
(42) Castle nut
(43) Dust seal
(44) Clip
(45) Tie-rod end
(46) Clip
(47) Boot
(48) Band
(49) Tie-rod
(50) Lock washer
(51) Pipe B
(52) Pipe A
(53) Steering body
(54) Oil seal
(55) Piston ring
(56) Rack
(57) Rack bushing
(58) Rack stopper
(59) Circlip
Tightening torque: N·m (kgf-m, ft-lb)
T1: 6 (0.6, 4.3)
T2: 7.4 (0.75, 5.4)
T3: 8 (0.8, 5.8)
T4: 13 (1.3, 9.4)
T5: 15 (1.5, 10.8)
T6: 18 (1.8, 13.0)
T7: 22 (2.2, 15.9)
T8: 24 (2.4, 17.4)
T9: 25 (2.5, 18.1)
T10: 27.0 (2.75, 19.9)
T11: 39 (4.0, 28.9)
T12: 52 (5.3, 38)
T13: 59 (6.0, 43)
T14: 78 (8.0, 58)
T15: 83 (8.5, 61.5)
PS-9
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

쐌RHD Model
S4M0232C
PS-10
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

(1) Eye bolt
(2) Pipe C
(3) Gasket
(4) Clip
(5) Pipe D
(6) Clamp E
(7) O-ring
(8) Cap
(9) Strainer
(10) Upper shell
(11) Buffle
(12) Seal washer
(13) Lower shell
(14) Pulley
(15) Oil pump
(16) Bracket
(17) Belt tension nut
(18) Bushing
(19) Belt cover
(20) Universal joint
(21) Dust cover
(22) Valve housing
(23) Oil seal
(24) Ball bearing
(25) Retaining ring
(26) Seal ring
(27) Valve sleeve
(28) Seal ring
(29) O-ring
(30) Oil seal
(31) Spacer
(32) Pinion
(33) Shim
(34) Adapter
(35) Clamp
(36) Castle nut
(37) Cotter pin
(38) Dust seal
(39) Clip
(40) Tie-rod end
(41) Clip
(42) Boot
(43) Wire
(44) Tie-rod
(45) Lock washer
(46) Holder
(47) Bushing
(48) Oil seal
(49) Oil seal
(50) O-ring
(51) Rack
(52) Oil seal
(53) Back-up washer
(54) Steering body
(55) Pipe A
(56) Pipe B
(57) Lock nut
(58) Adjusting screw
(59) Spring
(60) Sleeve
(61) Seat pad
Tightening torque: N·m (kgf-m, ft-lb)
T1: 7.4 (0.75, 5.4)
T2: 8 (0.8, 5.8)
T3: 13 (1.3, 9.4)
T4: 15 (1.5, 10.8)
T5: 18 (1.8, 13.0)
T6: 20 (2.0, 14.5)
T7: 22 (2.2, 15.9)
T8: 24 (2.4, 17.4)
T9: 24.5 (2.50, 18.1)
T10: 25 (2.5, 18.1)
T11: 27.0 (2.75, 19.9)
T12: 39 (4.0, 28.9)
T13: 59 (6.0, 43)
T14: 52 (5.3, 38)
T15: 64 (6.5, 47)
T16: 78 (8.0, 58)
T17: 83 (8.5, 61.5)
PS-11
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

3. POWER ASSISTED SYSTEM FOR TURBO MODEL S601001A0505
쐌LHD Model
S4M0566A
PS-12
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

(1) Eye bolt
(2) Pipe C
(3) Gasket
(4) Clip
(5) Pipe D
(6) Clamp E
(7) O-ring
(8) Cap
(9) Reservoir tank
(10) Reservoir tank bracket
(11) Pulley
(12) Oil pump
(13) Bracket
(14) Belt tension nut
(15) Bushing
(16) Belt cover
(17) Pipe E
(18) Pipe F
(19) Clamp plate
(20) Universal joint
(21) Dust cover
(22) Valve housing
(23) Gasket
(24) Oil seal
(25) Special bearing
(26) Seal ring
(27) Pinion and valve ASSY
(28) Oil seal
(29) Back-up washer
(30) Ball bearing
(31) Snap ring
(32) Lock nut
(33) Adjusting screw
(34) Spring
(35) Sleeve
(36) Adapter
(37) Clamp
(38) Cotter pin
(39) Castle nut
(40) Dust seal
(41) Clip
(42) Tie-rod end
(43) Clip
(44) Boot
(45) Band
(46) Tie-rod
(47) Lock washer
(48) Pipe B
(49) Pipe A
(50) Steering body
(51) Oil seal
(52) Piston ring
(53) Rack
(54) Rack bushing
(55) Rack stopper
(56) Circlip
(57) Suction hose
(58) Tank hose
Tightening torque: N·m (kgf-m, ft-lb)
T1: 6 (0.6, 4.3)
T2: 7.4 (0.75, 5.4)
T3: 8 (0.8, 5.8)
T4: 13 (1.3, 9.4)
T5: 15 (1.5, 10.8)
T6: 15 (1.5, 10.8)
T7: 15.7 (1.6, 11.6)
T8: 22 (2.2, 15.9)
T9: 24 (2.4, 17.4)
T10: 25 (2.5, 18.1)
T11: 25 (2.5, 18.1)
T12: 27 (2.75, 19.9)
T13: 37.3 (3.8, 27.5)
T14: 39 (4.0, 28.9)
T15: 59 (6.0, 43)
T16: 78 (8.0, 58)
T17: 83 (8.5, 61.5)
T18: 25 (2.5, 18.1)
PS-13
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

쐌RHD Model
S4M0567A
PS-14
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

(1) Eye bolt
(2) Pipe C
(3) Gasket
(4) Clip
(5) Pipe D
(6) Clamp E
(7) Cap
(8) Reservoir tank
(9) Reservoir tank bracket
(10) Pulley
(11) Oil pump
(12) Bracket
(13) Belt tension nut
(14) Bushing
(15) Belt cover
(16) Universal joint
(17) Dust cover
(18) Valve housing
(19) Oil seal
(20) Ball bearing
(21) Retaining ring
(22) Seal ring
(23) Valve sleeve
(24) Seal ring
(25) O-ring
(26) Oil seal
(27) Spacer
(28) Pinion
(29) Shim
(30) Adapter
(31) Clamp
(32) Castle nut
(33) Cotter pin
(34) Dust seal
(35) Clip
(36) Tie-rod end
(37) Clip
(38) Boot
(39) Wire
(40) Tie-rod
(41) Lock washer
(42) Holder
(43) Bushing
(44) Oil seal
(45) Seal ring
(46) O-ring
(47) Rack
(48) Oil seal
(49) Back-up ring
(50) Steering body
(51) Pipe A
(52) Pipe B
(53) Lock nut
(54) Adjusting screw
(55) Spring
(56) Sleeve
(57) Seat pad
(58) Suction hose
(59) Tank hose
Tightening torque: N·m (kgf-m, ft-lb)
T1: 7.4 (0.75, 5.4)
T2: 8 (0.8, 5.8)
T3: 13 (1.3, 9.4)
T4: 15 (1.5, 10.8)
T5: 15.7 (1.6, 11.6)
T6: 20 (2.0, 14.5)
T7: 22 (2.2, 15.9)
T8: 24 (2.4, 17.4)
T9: 24 (2.4, 17.4)
T10: 24.5 (2.50, 18.1)
T11: 25 (2.5, 18.1)
T12: 27.0 (2.75, 19.9)
T13: 37.3 (3.8, 27.5)
T14: 39 (4.0, 28.9)
T15: 59 (6.0, 43)
T16: 64 (6.5, 47)
T17: 78 (8.0, 58)
T18: 83 (8.5, 61.5)
PS-15
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

C: CAUTION S601001A03
쐌This section includes Airbag related repair
works. For those corresponding to the repair
procedures, read carefully CAUTION items in AB
section before working and be sure to follow the
instructions.
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.
쐌Be careful not to burn your hands, because each
part on the vehicle is hot after running.
쐌Use SUBARU genuine steering fluid, grease
etc. or the equivalent. Do not mix steering fluid,
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 steering fluid onto sliding or revolution
surfaces before installation.
쐌Before installing O-rings or snap rings, apply
sufficient amount of steering fluid 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.
PS-16
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

D: PREPARATION TOOL S601001A17
1. SPECIAL TOOLS S601001A1701
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2411
925700000 WRENCH 쐌Used for removing and installing tie-rod.
쐌Apply this tool to rack.
B4M2412
925711000 PRESSURE GAUGE Used for measuring oil pump pressure.
B4M2413
926200000 STAND Used when inspecting characteristic of gearbox
assembly and disassembling it.
B4M2414
34099AC010 ADAPTER HOSE A Used with PRESSURE GAUGE (925711000).
PS-17
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2415
34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000).
B4M2416
926230000 SPANNER 쐌For the lock nut when adjusting backlash of
gearbox.
쐌Measurement of rotating resistance of gear-
box assembly.
B4M2419
34199AE040 OIL CHARGE
GUIDE 쐌Used for charging power steering oil. 쐌For TURBO model
B4M2420
927640000 INSTALLER B 쐌Used for installing ball bearing into housing.
쐌For LHD model
B4M2421
926370000 INSTALLER A 쐌Used for installing valve assembly into valve
housing assembly.
쐌Used with STAND BASE (927630000).
쐌For LHD model
PS-18
GENERAL DESCRIPTION
Power Assisted System (Power Steering)

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2422
926390001 COVER &
REMOVER ASSY 쐌Used for assembling rack assembly. 쐌For LHD model
B4M2423
926420000 PLUG 쐌When oil leaks from pinion side of gearbox
assembly, remove pipe B from valve housing,
attach this tool and check oil leaking points.
쐌For LHD model
B4M2424
926400000 GUIDE 쐌Right side of rack when installing rack bush.
쐌Used with GUIDE (927660000).
쐌For LHD model
B4M2425
927660000 GUIDE 쐌Right side of rack when installing rack bush.
쐌Used with GUIDE (926400000).
쐌For LHD model
B4M2426
927620000 INSTALLER B 쐌Used for installing oil seal of valve housing.
쐌Used with INSTALLER A (926360000).
쐌For LHD model
PS-19
GENERAL DESCRIPTION
Power Assisted System (Power Steering)