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Subaru forester 2001 Service Manual
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Subaru forester 2001 Service Manual

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See also: Service Manual , Owner's Manual
2001 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, 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.
QUICK REFERENCE INDEX
G8050GE5

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Summary of Contents for Subaru forester 2001

  • Page 1 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.

  • Page 2: Table Of Contents

    FRONT SUSPENSION Page General Description..................2 Wheel Alignment ..................6 Front Transverse Link ................14 Front Ball Joint ..................17 Front Strut ....................18 Front Stabilizer ..................22 Front Crossmember ..................23 General Diagnostic Table ................24...

  • Page 3: General Description

    GENERAL DESCRIPTION Front Suspension 1. General Description S202001 A: SPECIFICATIONS S202001E49 1. STABILIZER S202001E4901 Bar dia. Model 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...
  • Page 4 GENERAL DESCRIPTION Front Suspension B: COMPONENT S202001A05 S4M0317B (1) Front crossmember (17) Dust seal Tightening torque: N·m (kgf-m, ft-lb) (2) Bolt ASSY (18) Strut mount 20 (2.0, 14.5) (3) Housing (19) Spacer 25 (2.5, 18.1) (4) Washer (20) Upper spring seat 30 (3.1, 22) (5) Stopper rubber (Rear) (21) Rubber seat...
  • Page 5 Avoid unnecessary removal, installation, disassembly, and replace- ment. ¼ Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. ¼ Be sure to tighten fasteners including bolts and nuts to the specified torque.
  • Page 6 GENERAL DESCRIPTION Front Suspension D: PREPARATION TOOL S202001A17 1. SPECIAL TOOLS S202001A1701 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927380002 ADAPTER Used as an adapter for camber & caster gauge when measuring camber and caster. (1) 28199AC000 PLATE (2) 28199AC010 BOLT B4M2378A 927680000 INSTALLER &...

  • Page 7: Wheel Alignment

    WHEEL ALIGNMENT 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...
  • Page 8 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”...
  • Page 9 WHEEL ALIGNMENT Front Suspension ¼ Front Camber Adjustment 2. CAMBER S202116A1002 ¼ Inspection 1) Loosen two self-locking nuts located at lower front portion of strut. 1) Place front wheel on turning radius gauge. CAUTION: Make sure ground contacting surfaces of front and ¼...
  • Page 10 WHEEL ALIGNMENT Front Suspension Left side Right side Rotate counterclock- Camber is increased. Rotate clockwise. wise. B4M0190 B4M0350 Rotate counterclock- Camber is decreased. Rotate clockwise. wise. B4M0350 B4M0190 3) Tighten the two self-locking nuts. 4. FRONT WHEEL TOE-IN S202116A1004 ¼ Inspection Tightening torque: 175 N·m (17.8 kgf-m, 129 ft-lb) 1) Using a toe gauge, measure front wheel toe-in.
  • Page 11 WHEEL ALIGNMENT Front Suspension ¼ Adjustment B − A = Toe-in 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.
  • Page 12 WHEEL ALIGNMENT Front Suspension Left side Right side Toe-in is Rotate counter- Rotate clockwise. increased. clockwise. B4M0192 B4M0352 Toe-in is Rotate counter- Rotate clockwise. decreased. clockwise. B4M0352 B4M0192 3) Tighten self-locking nut. 6. THRUST ANGLE S202116A1008 ¼ Inspection Tightening torque: 100 N·m (10.2 kgf-m, 74 ft-lb) 1) Position vehicle on a level surface.
  • Page 13 WHEEL ALIGNMENT Front Suspension ¼ Adjustment NOTE: Thrust angle refers to a mean value of left and right 1) Make thrust angle adjustments by turning toe-in rear wheel toe angles in relation to vehicle body adjusting bolts of rear suspension equally in the center line.
  • Page 14 WHEEL ALIGNMENT Front Suspension 7. STEERING ANGLE S202116A1005 ¼ Inspection 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.

  • Page 15: Front Transverse Link

    FRONT TRANSVERSE LINK Front Suspension 3. Front Transverse Link B: INSTALLATION S202113A11 S202113 1) Temporarily tighten the two bolts used to secure A: REMOVAL S202113A18 rear bushing of the transverse link to body. 1) Set the vehicle on the lift. NOTE: 2) Disconnect ground terminal from the battery.
  • Page 16 FRONT TRANSVERSE LINK Front Suspension NOTE: C: DISASSEMBLY S202113A06 ¼ Move rear bushing back and forth until trans- 1. FRONT BUSHING verse link-to-rear bushing clearance is established S202113A0601 (as indicated in figure.) before tightening. Using ST, press front bushing out of place. ¼...
  • Page 17 FRONT TRANSVERSE LINK Front Suspension D: ASSEMBLY E: INSPECTION S202113A02 S202113A10 1. FRONT BUSHING 1) Check transverse link for wear, damage and S202113A0201 cracks, and correct or replace if defective. To reassemble, reverse disassembly procedures. 2) Check bushings for cracks, fatigue or damage. CAUTION: 3) Check rear bushing for oil leaks.

  • Page 18: Front Ball Joint

    FRONT BALL JOINT Front Suspension 4. Front Ball Joint C: INSPECTION S202114A10 S202114 1) Measure play of ball joint by the following pro- A: REMOVAL S202114A18 cedures. Replace with a new one when the play 1) Set the vehicle on the lift. exceeds the specified value.

  • Page 19: Front Strut

    FRONT STRUT Front Suspension 5. Front Strut 7) Scribe an alignment mark on the camber S202115 adjusting bolt which secures strut to housing. A: REMOVAL 8) Remove bolt securing the ABS sensor harness S202115A18 on models equipped with ABS. 1) Set the vehicle on the lift. 2) Disconnect ground terminal from the battery.
  • Page 20 FRONT STRUT Front Suspension B: INSTALLATION C: DISASSEMBLY S202115A11 S202115A06 1) Install strut mount at upper side of strut to body 1) Using a coil spring compressor, compress coil and tighten with nuts. spring. Tightening torque: 20 N·m (2.0 kgf-m, 14.5 ft-lb) 2) Install ABS sensor harness to strut.
  • Page 21 FRONT STRUT Front Suspension 5) Set the coil spring correctly so that its end face D: ASSEMBLY S202115A02 fits well into the spring seat as shown. 1) Before installing coil spring, strut mount, etc., on the strut, check for the presence of air in the dampening force generating mechanism of the strut since air prevents proper dampening force from being produced.
  • Page 22 FRONT STRUT Front Suspension 5. HELPER E: INSPECTION S202115A1005 S202115A10 Replace it with new one if cracked or damaged. Check the disassembled parts for cracks, damage and wear, and replace with new parts if defective. 1. DAMPER STRUT S202115A1001 1) Check for oil leakage. 2) Move the piston rod up and down to check it operates smoothly without any binding.

  • Page 23: Front Stabilizer

    FRONT STABILIZER Front Suspension 6. Front Stabilizer B: INSTALLATION S202119A11 S202119 1) Install in the reverse order of removal. A: REMOVAL S202119A18 NOTE: 1) Set the vehicle on the lift. ¼ Install bushing (on front crossmember side) 2) Disconnect ground terminal from the battery. while aligning it with paint mark on stabilizer.

  • Page 24: Front Crossmember

    FRONT CROSSMEMBER Front Suspension 7. Front Crossmember 12) Support crossmember with a jack, remove S202108 nuts securing crossmember to body and lower A: REMOVAL crossmember gradually along with steering gear- S202108A18 box. 1) Set the vehicle on the lift. CAUTION: 2) Disconnect ground cable from the battery.

  • Page 25: General Diagnostic Table

    GENERAL DIAGNOSTIC TABLE Front Suspension 8. General Diagnostic Table S202121 A: INSPECTION S202121A10 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT S202121A1001 Possible causes Countermeasures (1) Permanent distortion or breakage of coil spring Replace. (2) Unsmooth operation of damper strut and/or shock absorber Replace.