2003 FORESTER SERVICE MANUAL

CHASSIS SECTION

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, reassembling, inspection and adjustment of components 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 genuine parts.

QUICK REFERENCE INDEX

FRONT SUSPENSION

REAR SUSPENSION

WHEEL AND TIRE SYSTEM

DIFFERENTIALS

TRANSFER CASE

DRIVE SHAFT SYSTEM

ABS

ABS (DIAGNOSTICS)

BRAKE

PARKING BRAKE

POWER ASSISTED SYSTEM

(POWER STEERING)

TC

DS

ABS

ABS

FS

RS

WT

DI

BR

PB

PS

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.

G8070GE5

FRONT SUSPENSION

FS

Page

1.

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

2.

Wheel Alignment .........................................................................................7

3.

Front Transverse Link ...............................................................................16

4.

Front Ball Joint ..........................................................................................18

5.

Front Strut .................................................................................................19

6.

Front Stabilizer ..........................................................................................23

7.

Front Crossmember ..................................................................................24

8.

Sub Frame ................................................................................................25

9.

General Diagnostic Table..........................................................................26

Rear

Diameter of stabilizer

Camber (Tolerance:

±0°45′)

Toe-in

Thrust angle

Wheel arch height (Tolerance:

+12

/

−24

mm (

+0.47

/

−0.94

in)

Diameter of stabilizer

GENERAL DESCRIPTION

FRONT SUSPENSION

1. General Description

A: SPECIFICATIONS

Front

Item

Camber (Tolerance:

±0°45′)

Caster (Reference)

Toe-in

Kingpin angle (Reference)

Wheel arch height (Tolerance:

+12

/

−24

mm (

+0.47

/

−0.94

in)

Non-turbo Turbo

−0°25′

3

°03′

0

±3 mm (0±0.12 in) Each toe angle: 0°±0°07′30″

13

°12′

437 mm

(17.20 in)

21 mm

(0.83 in)

−0°50′ −0°55′

2

±3 mm (0.079±0.118 in) Each toe angle: 0°05′±0°07′30″

0

°±30′

440 mm

(17.32 in)

435 mm

(17.13 in)

17 mm

(0.67 in)

NOTE:

• Front 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.

• The 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.

FS-00001

(1) Front

A

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

α = Each toe angle

FS-2

GENERAL DESCRIPTION

FRONT SUSPENSION

B: COMPONENT

(28)

(19)

T1

(17)

T6

(18)

(20)

(21)

(22)

(23)

(24)

(25)

(28)

T11

(26)

T8

(16)

T7

(29)

(1)

(15)

(14)

(13)

(28)

T2

T2

(2)

(11)

(28)

T4

T5

(3)

(5)

(4)

(28)

T12

T10

(28)

T9

(28)

(6)

(7)

(8)

(28)

T6

(9)

(27)

T4

(10)

T13

(12)

(29)

(31)

(30)

T8

T8

T6

FS-00057

FS-3

FRONT SUSPENSION

(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

(14) Bushing

(15) Stabilizer

(16) Jack up plate

GENERAL DESCRIPTION

(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) Sub frame

(30) Cover

(31) Clip

Tightening torque: N·m (kgf-m, ft-lb)

T1: 20 (2.0, 14.5)

T2: 25 (2.5, 18.1)

T3: 40 (4.1, 30) (Further tighten the bolts within 60

°°°° )

T4: 45 (4.6, 33)

T5: 50 (5.1, 37)

T6: 55 (5.6, 41)

T7: 70 (7.1, 51.6)

T8: 71 (7.2, 52)

T9: 100 (10.2, 74)

T10: 125 (12.7, 92.3)

T11: 175 (17.8, 129)

T12: 190 (19.4, 140)

T13: 250 (25.5, 184)

FS-4

GENERAL DESCRIPTION

C: CAUTION

• Wear working clothing, including a cap, protective goggles, and protective shoes during operation.

• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.

• Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers.

• Be sure to tighten fasteners including bolts and nuts to the specified torque.

• Place shop jacks or safety stands at the specified points.

• Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.

FRONT SUSPENSION

FS-5

FRONT SUSPENSION

D: PREPARATION TOOL

1. SPECIAL TOOLS

GENERAL DESCRIPTION

ILLUSTRATION TOOL NUMBER

927380001

DESCRIPTION

ADAPTER

REMARKS

Used as an adapter for camber & caster gauge when measuring camber and caster.

(1) 28199AC000 PLATE

(2) 28199AC010 BOLT

ST-927380001

927680000 INSTALLER &

REMOVER SET

Used for replacing transverse link bushing.

ST-927680000

927760000 STRUT MOUNT

SOCKET

Used for disassembling and assembling strut and shock mount.

ST-927760000

2. GENERAL PURPOSE TOOLS

Alignment gauge

Turning radius gauge

Toe-in gauge

Dial gauge

Coil spring compressor

TOOL NAME REMARKS

Used for wheel alignment measurement.

Used for wheel alignment measurement.

Used for toe-in measurement.

Used for damper strut measurement.

Used for strut disassembly/assembly.

FS-6

WHEEL ALIGNMENT

FRONT SUSPENSION

2. Wheel Alignment

A: INSPECTION

Check the following items before taking wheel alignment measurement.

Check items before taking wheel alignment measurement:

• tire air pressure

• unbalanced right and left tire wear, size difference

• tire run-out

• ball joint excessive play, wear

• tie rod end excessive play, wear

• wheel bearing excessive play

• right and left wheel base imbalance

• steering link part deformed, excessive play

• suspension part deformed, excessive play

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

Wheel arch height (Front and rear)

<Ref. to FS-8, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>

↓

Camber (Front and rear)

<Ref. to FS-9, CAMBER, INSPECTION, Wheel Alignment.>

↓

Caster (Front)

<Ref. to FS-10, CASTER, INSPECTION, Wheel Alignment.>

↓

Steering angle

<Ref. to FS-11, STEERING ANGLE, INSPECTION, Wheel Alignment.>

↓

Front wheel toe-in

<Ref. to FS-11, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.>

↓

Rear wheel toe-in

<Ref. to FS-12, REAR WHEEL TOE-IN, INSPECTION, Wheel Alignment.>

↓

Thrust angle

<Ref. to FS-14, THRUST ANGLE, INSPECTION, Wheel Alignment.>

FS-7

WHEEL ALIGNMENT

FRONT SUSPENSION

1. WHEEL ARCH HEIGHT

1) Set the vehicle on a level surface.

2) Set the vehicle to “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, service tools, and top up fuel tank.)

3) Set the steering wheel in a straight line, then remove the vehicle straight ahead more than 5 m (16 ft) to settle the suspension.

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

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

(2)

(1)

A

(3)

(1)

A

A

(6)

(7)

(4) (5)

(1)

(8)

(1) Wheel arch height

(2) Front fender

(3) Rear quarter

Turbo

Non-Turbo

(4)

(5)

(6)

Front wheel arch height

Rear wheel arch height

Flange bend line

(7)

(8)

Measuring point

End of spindle

437

+12

/

−24

Front

mm (17.20

+0.47

/

−0.94

Specified wheel arch height

in)

Rear

435

+12

/

−24

mm (17.13

+0.47

/

−0.94

in)

440

+12

/

−24

mm (17.32

+0.47

/

−0.94

in)

FS-00012

FS-8

WHEEL ALIGNMENT

2. CAMBER

• Inspection

1) Place the front wheel on turning radius gauge.

Make sure ground contacting surfaces of front and rear wheels are set at the same height.

2) Set the ST into the center of wheel, and then install the wheel alignment gauge.

ST 927380001 ADAPTER

FRONT SUSPENSION

NOTE:

Moving the adjusting bolt by one scale graduation changes camber by approx. 0

°10′.

(4) (5)

(1)

(6) (7)

FS-00007

(1) Alignment gauge

(2) Turning radius gauge

3) Follow the wheel alignment gauge operation manual to measure camber angle.

NOTE:

Refer to the “SPECIFICATIONS” for camber values.

Front: <Ref. to FS-2, SPECIFICATIONS, General

Description.>

Rear: <Ref. to RS-2, SPECIFICATIONS, General

Description.>

• Front Camber Adjustment

1) Loosen the two self-locking nuts located at lower front portion of strut.

NOTE:

When adjusting bolt needs to be loosened or tightened, hold its head with a wrench and turn selflocking nut.

2) Turn the camber adjusting bolt so that camber is set at the specification.

(2)

(3)

(1) Strut

(2) Adjusting bolt

(3) Housing

(4) Outer

(5) Inner

(6) Camber is increased.

(7) Camber is decreased.

FS-00008

FS-9

WHEEL ALIGNMENT

FRONT SUSPENSION

Camber is increased.

Rotate camber adjusting bolt LH counterclockwise.

Rotate camber adjusting bolt RH clockwise.

FS-00009 FS-00010

Rotate camber adjusting bolt LH clockwise.

Camber is decreased

Rotate camber adjusting bolt RH counterclockwise.

FS-00010

3) Tighten new two self-locking nuts.

Tightening torque:

175 N·m (17.8 kgf-m, 129 ft-lb)

3. CASTER

• Inspection

1) Place the front wheel on turning radius gauge.

Make sure ground contacting surfaces of front and rear wheels are set at the same height.

FS-00009

2) Set the ST into the center of wheel, and then install the wheel alignment gauge.

ST 927380001 ADAPTER

FS-10

FS-00007

(1) Alignment gauge

(2) Turning radius gauge

3) Follow the wheel alignment gauge operation manual to measure caster angle.

NOTE:

Refer to the “SPECIFICATIONS” for caster values.

<Ref. to FS-2, SPECIFICATIONS, General Description.>

WHEEL ALIGNMENT

4. STEERING ANGLE

• Inspection

1) Place the vehicle on a turning radius gauge.

2) While depressing the brake pedal, turn the steering wheel fully to the right and left. With the steering wheel held at each fully turned position, measure both the inner and outer wheel steering angle.

Steering angle:

Inner wheel

Outer wheel

36

°°°°24′′′′±±±±1°°°°30′′′′

32

°±1°°°°30′′′′

• Adjustment

1) Turn the tie-rod to adjust steering angle of both inner and outer wheels.

2) Check the toe-in.

NOTE:

Correct the boot if it is twisted.

FRONT SUSPENSION

4) Measure the distance “B” between right and left marks. Toe-in can then be obtained by the following equation:

A

−−−− B = Toe-in

FS-00015

• Adjustment

1) Make sure that the right and left steering angles are within specified value.

2) Loosen the right and left side steering tie-rods lock nuts.

3) Turn the right and left tie rods equal amounts until the toe-in is at the specification.

Both the right and left tie-rods are right-hand threaded. To increase toe-in, turn both tie-rods clockwise equal amounts (as viewed from inside of the vehicle).

FS-00014

(1) Lock nut

5. FRONT WHEEL TOE-IN

• Inspection

Toe-in:

0

±±±±3 mm (0±±±±0.12 in)

1) Set the toe-in gauge to rear sides of right and left front tires at height correspanding to center of spindle.

2) Mark eath right and left tires at height correspanding to center of spindle and measure the distance

“A” between marks.

3) Move the vehicle forward to rotate wheels 180

°.

NOTE:

Whenever rotating the wheels, drive the vehicle forward.

(1) Lock nut

4) Tighten the tie-rod lock nut.

Tightening torque:

85 N·m (8.7 kgf-m, 62.9 ft-lb)

NOTE:

Correct the tie-rod boot, if it is twisted.

FS-00014

FS-11

WHEEL ALIGNMENT

FRONT SUSPENSION

6. REAR WHEEL TOE-IN

• Inspection

Toe-in:

2

±±±±3 mm (0.079±±±±0.118 in)

For rear toe-in inspection procedure, refer to

FRONT WHEEL TOE-IN procedure. <Ref. to FS-

11, FRONT WHEEL TOE-IN, INSPECTION,

Wheel Alignment.>

• Adjustment

1) Loosen the self-locking nut on inner side of link rear.

NOTE:

When loosening or tightening the adjusting bolt, hold the bolt head and turn self-locking nut.

FS-00017

(1) Adjusting bolt

(2) Link rear

2) Turn the adjusting bolt head until toe-in is at the specification.

NOTE:

When right and left wheels are adjusted for toe-in at the same time, the movement of one scale graduation changes toe-in by approx. 1.5 mm (0.6 in).

FS-12

WHEEL ALIGNMENT

FRONT SUSPENSION

Rotate camber adjusting bolt LH clockwise.

Toe-in is increased.

Rotate camber adjusting bolt RH counterclockwise.

FS-00018

Toe-in is decreased.

Rotate camber adjusting bolt LH counterclockwise.

Rotate camber adjusting bolt RH clockwise.

FS-00019

FS-00018

3) Tighten a new self-locking nut.

Tightening torque:

100 N·m (10.2 kgf-m, 74 ft-lb)

FS-00019

FS-13

WHEEL ALIGNMENT

FRONT SUSPENSION

7. THRUST ANGLE

• Inspection

1) Position the vehicle on a level surface.

2) Move the vehicle 3 to 4 m (10 to 13 ft) directly forward.

3) Determine the center lines of front axle loci and rear axle loci.

4) Measure the distance “L” between center line of loci of the axles.

Thrust angle:

Less than 30

′′′′ when “L” is less than 22 mm

(0.9 in).

3) When the right and left adjusting bolts are turned incrementally by one graduation in the same direction, the thrust angle will change approx. 16

′ [“L” is almost equal to 12 mm (0.472 in)].

Thrust angle:

0

°±

FS-00022

(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)

• Adjustment

1) Make the 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 toeout direction, in order to make thrust angle adjustment.

FS-00022

(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)

NOTE:

Thrust angle refers to a mean value of right and left rear wheel toe angles in relation to the vehicle body center line. Vehicle is driven straight in the thrust angle direction while swinging in the oblique direction depending on the degree of the mean thrust angle.

FS-00024

(1) Front

(2) Thrust angle

(3) Body center line

FS-14

WHEEL ALIGNMENT

Thrust angle:

γγγγ = (αααα −−−− ββββ)/2

α: Right rear wheel toe-in angle

β: Left rear wheel toe-in angle

Here, use only positive toe-in values from each wheel to substitute for

α and β in the equation.

FRONT SUSPENSION

(1) Front

(2) Body center line

FS-00025

FS-15

FRONT TRANSVERSE LINK

FRONT SUSPENSION

3. Front Transverse Link

A: REMOVAL

1) Set the vehicle on the lift.

2) Lift-up the vehicle and remove the wheel.

3) Remove the sub frame.

4) Disconnect the stabilizer link from transverse link.

5) Remove the bolt securing ball joint of transverse link to housing.

B: INSTALLATION

1) Temporarily tighten the two bolts used to secure rear bushing of 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 bushing).

2) Install the bolts used to connect transverse link to crossmember and temporarily tighten with a new self-locking nut.

3) Insert the ball joint into housing.

4) Connect the stabilizer link to transverse link, and temporarily tighten a new self-locking nut.

FS-00026

6) Remove the nut (do not remove bolt) securing transverse link to crossmember.

7) Remove the two bolts securing bushing bracket of transverse link to the vehicle body at rear bushing location.

FS-00027

8) Extract the ball joint from housing.

9) Remove the bolt securing transverse link to crossmember, and then extract the transverse link from crossmember.

FS-00026

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:

45 N·m (4.6 kgf-m, 33 ft-lb)

(2) Transverse link and crossmember

Tightening torque:

125 N·m (12.7 kgf-m, 92.3 ft-lb)

(3) Transverse link rear bushing and body

Tightening torque:

100 N·m (10.2 kgf-m, 74 ft-lb)

6) Check the wheel alignment and adjust if necessary.

FS-00028

FS-16

C: DISASSEMBLY

FRONT TRANSVERSE LINK

1. FRONT BUSHING

Using the ST, press the front bushing out of place.

ST 927680000 INSTALLER & REMOVER

SET

FRONT SUSPENSION

D: ASSEMBLY

1. FRONT BUSHING

Assemble in the reverse order of disassembly.

CAUTION:

Install the front bushing in correct direction, as shown in the figure.

(1)

(2)

(3)

FS-00031

2. REAR BUSHING

1) Scribe an aligning mark on the transverse link and rear bushing.

2) Loosen the nut and remove rear bushing.

FS-00032

FS-00016

(1) Face bushing toward center of ball joint

(2) Ball joint

(2) 90

°±3°

2. REAR BUSHING

1) Install the rear bushing to transverse link and align aligning marks scribed on the two.

2) Tighten a new self-locking nut.

NOTE:

While holding the rear bushing so as not to change position of aligning marks, tighten the self-locking nut.

Tightening torque:

190 N·m (19.4 kgf-m, 140 ft-lb)

E: INSPECTION

1) Check the transverse link for wear, damage and cracks, and correct or replace if defective.

2) Check the bushings for cracks, fatigue or damage.

3) Check the rear bushing for oil leaks.

FS-17

FRONT BALL JOINT

FRONT SUSPENSION

4. Front Ball Joint

A: REMOVAL

1) Remove the wheel.

2) Pull out the cotter pin from ball stud, remove the castle nut, and extract the ball stud from transverse link.

3) Remove the bolt securing ball joint to housing.

C: INSPECTION

1) Measure the play of ball joint by the following procedures. Replace with a new one when the play exceeds specified value.

(1) With 686 N (70 kgf, 154 lb) loaded in direction shown in the figure, measure the dimension

2

1

.

FS-00034

4) Extract the ball joint from housing.

B: INSTALLATION

1) Install the ball joint onto housing.

Tightening 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 the ball joint to transverse link.

Tightening torque (Castle nut):

40 N·m (4.1 kgf-m, 30 ft-lb)

3) Retighten the castle nut further within 60

° until a slot in castle nut is aligned with the hole in ball stud end, then insert a new cotter pin and bend it around castle nut.

4) Install the front wheel.

FS-00035

(2) With 686 N (70 kgf, 154 lb) loaded in opposite direction shown in the figure, measure the dimension

2

2

.

FS-00036

(3) Calculate plays from the following formula.

S =

2

2

−

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 the play is smaller than specified value, visually inspect the dust cover.

If the dust cover is damaged, replace with a new ball joint.

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.

FS-18

5. Front Strut

FRONT STRUT

FRONT SUSPENSION

6) Remove the three nuts securing strut mount to body.

A: REMOVAL

1) Remove the wheel.

2) Remove the bolt securing brake hose from strut.

FS-00037

3) Scribe an alignment mark on the camber adjusting bolt which secures strut to housing.

4) Remove the bolt securing ABS sensor harness.

FS-00038

5) Remove the two bolts securing housing to strut.

NOTE:

While holding the head of adjusting bolt, loosen self-locking nut.

FS-00039

B: INSTALLATION

1) Install the strut mount at upper side of strut to body, and then tighten with nuts.

Tightening torque:

20 N·m (2.0 kgf-m, 14.5 ft-lb)

2) Position the aligning mark on camber adjustment bolt with aligning mark on lower side of strut.

Install the strut to housing with a new self-locking nut.

NOTE:

While holding the head of adjusting bolt, tighten self-locking nut.

Tightening torque:

175 N·m (17.8 kgf-m, 129 ft-lb)

3) Install the ABS sensor harness to strut.

Tightening torque:

33 N·m (3.4 kgf-m, 24.3 ft-lb)

4) Install the bolts which secure brake hose to strut.

Tightening torque:

33 N·m (3.4 kgf-m, 24.3 ft-lb)

5) Install the wheels.

NOTE:

Check the wheel alignment and adjust if necessary.

FS-19

FRONT STRUT

FRONT SUSPENSION

C: DISASSEMBLY

1) Using a coil spring compressor, compress the coil spring.

(4) Fully contract the piston rod.

(5) Repeat three or four times from the first step.

NOTE:

After completely purging air from the strut, be sure to place the strut with piston rod facing up. If it is laid down, check for entry of air in the strut as outlined under “Checking for the presence of air”.

4) Using a coil spring compressor, compress the coil spring.

NOTE:

Make sure that the installing direction of coil spring is as shown in the figure.

FS-00040

2) Using the ST, remove the self-locking nut.

ST 927760000 STRUT MOUNT SOCKET

FS-00041

3) Remove the strut mount, upper spring seat and rubber seat from strut.

4) Gradually decreasing the compression force of compressor, and then remove the coil spring.

5) Remove the dust cover and helper spring.

D: ASSEMBLY

1) Before installing the coil spring, strut mount, etc., on the strut, check for the presence of air in the damping force generating mechanism of the strut since air prevents proper damping force from being produced.

2) Checking for the presence of air

(1) Place the strut vertically with piston rod facing up.

(2) Move the piston rod to center of its entire stroke.

(3) While holding the piston rod end with fingertips, move the rod up and down.

(4) If the piston rod moves at least 10 mm (0.39

in) in the former step, purge air from the strut.

3) Air purging procedure

(1) Place the strut vertically with piston rod facing up.

(2) Fully extend the piston rod.

(3) With the piston rod fully extended, place the piston rod side down. The strut must stand vertically.

FS-20

FS-00042

(1) Flat (top side)

(2) Identification paint

(3) Inclined (bottom side)

5) Set the coil spring correctly so that its end face fits well into the spring seat as shown in the figure.

FS-00043

(1) Coil spring end face

6) Install the helper and dust cover to the piston rod.

7) Pull the piston rod fully upward, and install the rubber seat and spring seat.

FRONT STRUT

NOTE:

Ensure that upper spring seat is positioned as shown in the figure.

FS-00044

FRONT SUSPENSION

E: INSPECTION

Check the disassembled parts for cracks, damage and wear, and replace with new parts if defective.

1. DAMPER STRUT

1) Check for oil leakage.

2) Move the piston rod up and down to check that it operates smoothly without any binding.

3) Play of piston rod

• Measure the play as follows:

Fix outer shell and fully extend the rod. Set a dial gauge at the end of rod: L [10 mm (0.39 in)], then apply a force of W [20 N (2 kgf, 4 lb)] to threaded portion. With the force of 20 N (2 kgf, 4 lb) applied, read dial gauge indication: P

1

. Apply a force of 20 N

(2 kgf, 4 lb) in the opposite direction of “W”, then read dial gauge indication: P

2

.

(1) Outside of body

8) Install the strut mount to the piston rod, and then tighten a new self-locking nut temporarily.

9) Using a hexagon wrench to prevent strut rod from turning, tighten the self-locking nut with ST.

ST 927760000 STRUT MOUNT SOCKET

Tightening torque:

55 N·m (5.6 kgf-m, 41 ft-lb)

10) Loosen the coil spring carefully.

FS-00041

FS-00046

Limit of play (P

1

+ P

2

) :

0.8 mm (0.031 in)

If the play is greater than limit, replace the strut.

2. STRUT MOUNT

Check the rubber part for creep, cracks and deterioration, and replace it with a new one if defective.

3. DUST COVER

If any cracks or damage are found, replace it with a new one.

4. COIL SPRING

One having permanent strain should be replaced with a new one. When the vehicle posture is uneven, although there are no considerable reasons like tire puncture, uneven loading, etc., check the coil spring for its free length referring to specifications, cracks, etc., and replace it with a new one if defective.

5. HELPER

Replace it with a new one if cracked or damaged.

FS-21

FRONT STRUT

FRONT SUSPENSION

F: DISPOSAL

CAUTION:

• Before handling gas filled struts, be sure to wear goggles to protect eyes from gas, oil and/ or filings.

• Do not disassemble the strut damper or place into a fire.

• Drill holes before disposing of gas filled struts.

1) Place the gas filled strut on a flat and level surface with piston rod fully extended.

2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill, make holes in areas shown in the figure.

(1)

(1) 40 mm (1.57 in)

FS-00047

FS-22

6. Front Stabilizer

FRONT STABILIZER

FRONT SUSPENSION

• Ensure that bushing and stabilizer have the same identification colors when installing.

A: REMOVAL

1) Jack up the front part of the vehicle and support it with safety stands (rigid racks).

2) Remove the jack up plate from lower part of crossmember.

3) Remove the sub frame.<Ref. to FS-25, REMOV-

AL, Sub Frame.>

4) Remove the nut which secures stabilizer link to front transverse link.

FS-00050

FS-00048

5) Remove the bolt and nut which secure stabilizer to crossmember.

(1) Mark stamped on stabilizer

(2) Bushing identification color

2) Always tighten the rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight.

Tightening torque:

Jack up plate to crossmember:

70 N·m (7.1 kgf-m, 51.6 ft-lb)

Stabilizer link to front transverse link:

45 N·m (4.6 kgf-m, 33 ft-lb)

Stabilizer to crossmember:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

C: INSPECTION

1) Check the bushing for cracks, fatigue or damage.

2) Check the stabilizer link for deformities or damage.

FS-00049

B: INSTALLATION

1) Install in the reverse order of removal.

NOTE:

• Install the bushing (on front crossmember side) while aligning it with paint mark on stabilizer.

FS-23

FRONT CROSSMEMBER

FRONT SUSPENSION

7. Front Crossmember

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Lift-up the vehicle, and then remove the front tires and wheels.

3) Remove the sub frame.

4) Remove both the stabilizer and jack up plate.

FS-00051

(1) Front stabilizer

(2) Front crossmember

5) Disconnect the tie-rod end from housing.

6) Remove the front exhaust pipe.

7) Remove the front transverse link from front crossmember and body.

B: INSTALLATION

1) Install in the reverse order of removal.

NOTE:

Always tighten the rubber bushing when wheels are in full contact with the ground and vehicle is curb weight.

Tightening torque:

Transverse link bushing to crossmember:

100 N·m (10.2 kgf-m, 74 ft-lb)

Stabilizer to bushing:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

Tie-rod end to housing:

27.0 N·m (2.75 kgf-m, 19.9 ft-lb)

Front cushion rubber to crossmember:

85 N·m (8.7 kgf-m, 62.7 ft-lb)

Universal joint to pinion shaft:

24 N·m (2.4 kgf-m, 17.4 ft-lb)

Crossmember to body:

100 N·m (10.2 kgf-m, 74 ft-lb)

2) Purge air from the power steering system.

NOTE:

Check the wheel alignment and adjust if necessary.

C: INSPECTION

Check the crossmember for wear, damage and cracks, and correct or replace if defective.

FS-00028

8) Remove the nuts attaching engine mount cushion rubber to crossmember.

9) Remove the steering universal joint.

10) Disconnect the power steering pipe from steering gear box.

11) Lift the engine by approx. 10 mm (0.39 in) by using chain block.

12) Support the crossmember with a jack, remove nuts securing crossmember to body and lower the crossmember gradually along with steering gearbox.

CAUTION:

When removing the crossmember downward, be careful that tie-rod end does not interfere with SFJ boot.

FS-24

8. Sub Frame

A: REMOVAL

1) Lift-up the vehicle.

2) Remove the under cover.

3) Remove the bolt cover.

4) Remove the clip.

(6)

(4) (2)

FS-00053

SUB FRAME

FRONT SUSPENSION

B: INSTALLATION

Install in the reverse order of removal.

NOTE:

Replace the M12 bolt with a new one.

Tightening torque:

T1: 55 N·m (5.6 kgf-m, 41 ft-lb)

T2: 71 N·m (7.2 kgf-m, 52 ft-lb)

(1)

T2

(2)

(4)

(1)

(3)

FS-00054

5) Remove the sub frame.

NOTE:

Loosen bolt (1) and leave a few threads caught, then remove the bolts in the order of (2), (3), (4),

(5), and (6).

(1)

T2

(1)

T1

T1

T2

T2

FS-00056

(1) M10

× 30 bolt

(2) M12

× 87 bolt (with wax)

(3) M12

× 65 bolt (with wax)

(4) M10

× 90 bolt

C: INSPECTION

1) Check that there is no damage and distortion at the sub frame.

2) Check that the bolts are tightened with the specified torque. If there is looseness, tighten to the specified torque.

Tightening torque:

T1: 55 N·m (5.6 kgf-m, 41 ft-lb)

T2: 71 N·m (7.2 kgf-m, 52 ft-lb)

(1)

T2

(2)

(4)

(1)

(3)

(1)

(6)

(6)

(5)

(3)

(1)

T2

(1)

T1

T1

T2

T2

FS-00056

FS-00055

(1) M10

× 30 bolt

(2) M12

× 87 bolt (with wax)

(3) M12

× 65 bolt (with wax)

(4) M10

× 90 bolt

FS-25

GENERAL DIAGNOSTIC TABLE

FRONT SUSPENSION

9. General Diagnostic Table

A: INSPECTION

1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT

Possible causes

(1) Permanent distortion or breakage of coil spring

(2) Unsmooth operation of damper strut and/or shock absorber

(3) Installation of wrong strut and/or shock absorber

(4) Installation of wrong coil spring

2. POOR RIDE COMFORT

1) Large rebound shock

2) Rocking of the vehicle continues too long after running over bump and/or hump.

3) Large shock in bumping

Possible causes

(1) Breakage of coil spring

(2) Overinflation pressure of tire

(3) Improper wheel arch height

(4) Fault in operation of damper strut and/or shock absorber

(5) Damage or deformation of strut mount and/or shock absorber mount

(6) Unsuitable installation (maximum and/or minimum length) of damper strut and/or shock absorber.

(7) Deformation or damage of bushing

(8) Deformation or damage of helper in strut assembly and/or shock absorber

(9) Oil leakage of damper strut and/or shock absorber

Replace.

Replace.

Replace.

Countermeasures

Replace.

Adjust.

Adjust or replace the coil springs with new ones.

Replace.

Replace.

Replace with proper parts.

3. NOISE

Countermeasures

Replace.

Replace.

Replace with proper parts.

Replace with proper parts.

Possible causes Countermeasures

(1) Wear or damage of damper strut and/or shock absorber component parts Replace.

(2) Loosening of suspension link installing bolt Retighten to the specified torque.

(3) Deformation or loss of bushing

(4) Unsuitability of maximum and/or minimum length of damper strut and/or shock absorber

Replace.

Replace with proper parts.

(5) Breakage of coil spring

(6) Wear or damage of ball joint

(7) Deformation of stabilizer clamp

Replace.

Replace.

Replace.

FS-26