2003 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
Contents
1. BOXEO 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 un til 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 4 Tighten the tie rod lock nut Tightening torque 85 N m 8 7 kgf m 62 9 ft Ib NOTE Correct the tie rod boot if it is twisted 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 gradua tion changes toe in by approx 1 5 mm 0 6 in FS 12 WHEEL ALIGNMENT FRONT SUSPENSION Toe in is increased Rotate camber adj2. 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 Sete Ai et LS 7 EZS h 8 Remove the nuts attaching engine mount cush ion rubber to crossmember 9 Remove the steering universal joint 10 Disconnect the power steering pipe from steer ing 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 gear box CAUTION When removing the crossmember downward be careful that tie rod end does not interfere with SFJ boot 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 Ib Stabilizer to bushing 25 N m 2 5 kgf m 18 1 ft Ib Tie rod end to housing 27 0 N m 2 75 kgf m 19 9 ft Ib Front cushion rubber to crossmember 85 N m 8 7 kgf m 62 7 ft Ib Universal joint to pinion shaft 24 N m 2 4 kgf m 17 4 ft Ib Crossmember to body 100 N m 10 2 kgf m 74 ft Ib 2 Purge air from the power steering system NOTE Check the wheel alignment and adjust if necessary C IN
3. 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 direc tion depending on the degree of the mean thrust angle 1 4 2 FS 00024 1 Front 2 Thrust angle 3 Body center line FS 14 WHEEL ALIGNMENT FRONT SUSPENSION Thrust angle y a 2 Right rear wheel toe in angle B Left rear wheel toe in angle Here use only positive toe in values from each wheel to substitute for and p in the equation 1 2 V 5 00025 1 Front 2 Body center line 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 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 bush ing location FS 00027 8 Extract the ball joint from housing 9 Remove the bolt securing transverse link to cro
4. FS 00046 Limit of play P2 0 8 0 031 If the play is greater than limit replace the strut 2 STRUT MOUNT Check the rubber part for creep cracks and deteri oration 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 un even although there are no considerable reasons like tire puncture uneven loading etc check the coil spring for its free length referring to specifica tions 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 Donotdisassemble 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 sur face 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 2 PM 1 FS 00047 1 40 mm 1 57 in FS 22 FRONT STABILIZER 6 Front Stabilizer A REMOVAL 1 Jack up the front part of the vehicle and support it with safety stands rigid racks 2 Remove th
5. 01 ADAPTER 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 De scription gt FS 10 WHEEL ALIGNMENT FRONT SUSPENSION 4 STEERING ANGLE Inspection 1 Place the vehicle on a turning radius gauge 2 While depressing the brake pedal turn the steer ing 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 36924721930 Outer wheel 3291930 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 FS 00014 1 Lock nut 5 FRONT WHEEL TOE IN Inspection Toe in 0 3 mm 040 12 in 1 Set the toe in gauge to rear sides of right and left front tires at height correspanding to center of spin dle 2 Mark eath right and left tires at height correspan ding 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 for ward 4 Measure the distance B between right and left marks Toe in can then be obtained by the follow ing equation B Toe in
6. 2003 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS 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 reas sembling inspection and adjustment of 5 components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual ABS DIAGNOSTICS fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition BRAKE When replacement of parts during repair work is needed be sure to use SUBARU genuine parts PARKING BRAKE TRANSFER CASE DRIVE SHAFT SYSTEM POWER ASSISTED SYSTEM POWER STEERING All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD G8070GE5 SSS ti FRONT SUSPENSION Meo OX O Page General Description urne eer nenne rtm nnn ranura rn ha ns e rea QE aX aa R imue 2 Wheel tem tee 7 Front Transverse 1 1 enne nnne nnn 16 Front Ball JOA oe trece t rect cer See dees 18 Eront SU
7. RONT 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 in figure below to determine a point directly above center of wheel 5 Measure the distance between measuring point A and center of wheel 7 1 M 8 ss FS 00012 1 Wheel arch height 4 Front wheel arch height 7 Measuring point 2 Front fender b Rear wheel arch height 8 End of spindle 3 Rear quarter 6 Flange bend line Specified wheel arch height Front Rear 435 mm 1 7 13 10 477 0 94 in 437 mm 17 20 47 _9 in Non Turbo 440 mm 17 32 47 _9 gq in FS 8 WHEEL ALIGNMENT FRONT SUSPENSION 2 CAMBER NOTE Moving the adjusting bolt by one scale graduation Inspection changes camber by approx 0910 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 in stall the wheel alignment gauge ST 927380001 ADAPTER
8. SPECTION Check the crossmember for wear damage and cracks and correct or replace if defective FS 24 SUB FRAME 8 Sub Frame A REMOVAL 1 Lift up the vehicle 2 Remove the under cover 3 Remove the bolt cover a 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 FRONT SUSPENSION B INSTALLATION Install in the reverse order of removal NOTE Replace the M12 bolt with a new one Tightening torque T1 55 5 6 kgf m 41 ft lb T2 71 N m 7 2 kgf m 52 ft Ib Fd FE FS 00056 1 M10 x 30 bolt 2 M12 x 87 bolt with wax 3 M12 65 bolt with wax 4 M10 x 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 spec ified torque If there is looseness tighten to the specified torque Tightening torque T1 55 N m 5 6 kgf m 41 ft Ib T2 71 N m 7 2 kgf m 52 ft Ib M10 x 30 bolt M12 x 87 bolt with wax M12 x 65 bolt with wax M10 x 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 cause
9. cations check suspension parts and con nections for deformities replace with new ones as required FS 2 FS 00001 1 Front A Positive Toe in Negative Toe out Each toe angle GENERAL DESCRIPTION FRONT SUSPENSION B COMPONENT FS 00057 FS 3 GENERAL DESCRIPTION FRONT SUSPENSION 1 Front crossmember 17 Dust seal Tightening torque N m kgf m ft Ib 2 Bolt ASSY 18 Strut mount 1 20 2 0 14 5 3 Housing 19 Spacer T2 25 2 5 18 1 4 Washer 20 Upper spring seat T3 40 4 1 30 Further tighten the 5 Stopper rubber Rear 21 Rubber seat bolts within 60 6 Rear bushing 22 Dust cover T4 45 4 6 33 7 Stopper rubber Front 23 Helper T5 50 5 1 37 8 Ball joint 24 Coil spring T6 55 5 6 41 9 Transverse link 25 Damper strut T7 70 7 1 51 6 10 Cotter pin 26 Adjusting bolt T8 71 7 2 52 11 Front bushing 27 Castle nut T9 100 10 2 74 12 Stabilizer link 28 Self locking nut T10 125 12 7 92 3 13 Clamp 29 Sub frame T11 175 17 8 129 14 Bushing 30 Cover T12 190 19 4 140 15 Stabilizer 31 Clip T13 250 25 5 184 16 Jack up plate FS 4 GENERAL DESCRIPTION FRONT SUSPENSION C CAUTION Wear working clothing includ
10. e 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 00048 5 Remove the bolt and nut which secure stabilizer to crossmember 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 FRONT SUSPENSION Ensure that bushing and stabilizer have the same identification colors when installing 2 FS 00050 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 vehi cle is curb weight Tightening torque Jack up plate to crossmember 70 N m 7 1 kgf m 51 6 ft Ib Stabilizer link to front transverse link 45 N m 4 6 kgf m 33 ft Ib Stabilizer to crossmember 25 N m 2 5 kgf m 18 1 ft Ib C INSPECTION 1 Check the bushing for cracks fatigue or dam age 2 Check the stabilizer link for deformities or dam age FS 23 FRONT CROSSMEMBER FRONT SUSPENSION T 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
11. ing a cap protec tive goggles and protective shoes during opera tion Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Use SUBARU genuine grease etc or the equiv alent 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 cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vise FS 5 GENERAL DESCRIPTION FRONT SUSPENSION D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927380001 ST 927380001 ADAPTER Used as an adapter for camber amp caster gauge when measuring camber and caster 1 28199AC000 PLATE 2 28199AC010 BOLT 927680000 X amp ST 927680000 INSTALLER amp REMOVER SET Used for replacing transverse link bushing 927760000 amp ST 927760000 2 GENERAL PURPOSE TOOLS TOOL NAME STRUT MOUNT SOCKET Used for disassembling and assembling strut and shock mount REMARKS Alignment gauge Used for wheel alignment measurement Turning radius gauge Used for wheel alignment measurement Toe in gauge Used for toe in measurement Dia
12. j FS 00007 1 Alignment gauge 2 Turning radius gauge 3 Follow the wheel alignment gauge operation manual to measure camber angle FS 00008 NOTE Refer to the SPECIFICATIONS for camber val 1 Strut ues 2 Adjusting bolt Front lt Ref to FS 2 SPECIFICATIONS General 3 Housing Description gt 4 Outer Rear lt Ref to RS 2 SPECIFICATIONS General 5 Inner Description 6 Camber is increased Front Camber Adjustment 7 Camber is decreased 1 Loosen the two self locking nuts located at lower front portion of strut NOTE When adjusting bolt needs to be loosened or tight ened hold its head with a wrench and turn self locking nut 2 Turn the camber adjusting bolt so that camber is set at the specification FS 9 WHEEL ALIGNMENT FRONT SUSPENSION Camber is increased Rotate camber adjusting bolt LH counterclockwise Rotate camber adjusting bolt RH clockwise FS 00009 Camber is FS 00010 decreased Rotate camber adjusting bolt LH clockwise 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 Ib 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 in stall the wheel alignment gauge ST 9273800
13. l gauge Used for damper strut measurement Coil spring compressor FS 6 Used for strut disassembly assembly WHEEL ALIGNMENT FRONT SUSPENSION 2 Wheel Alignment A INSPECTION Check the following items before taking wheel tie rod end excessive play wear alignment measurement wheel bearing excessive play Check items before taking wheel alignment mea right and left wheel base imbalance surement steering link part deformed excessive play tire air pressure suspension part deformed excessive play unbalanced right and left tire wear size differ Check adjust and or measure the wheel alignment ence in accordance with procedures indicated in the fig tire run out ure ball joint excessive play wear Wheel arch height Front and rear Ref to FS 8 WHEEL ARCH HEIGHT INSPECTION Wheel Alignment Uu Camber Front and rear Ref to FS 9 CAMBER INSPECTION Wheel Alignment gt Uu Caster Front Ref to FS 10 CASTER INSPECTION Wheel Alignment Uu Steering angle Ref to FS 11 STEERING ANGLE INSPECTION Wheel Alignment Uu Front wheel toe in Ref to FS 11 FRONT WHEEL TOE IN INSPECTION Wheel Alignment Uu Rear wheel toe in Ref to FS 12 REAR WHEEL INSPECTION Wheel Alignment Uu Thrust angle Ref to FS 14 THRUST ANGLE INSPECTION Wheel Alignment FS 7 WHEEL ALIGNMENT F
14. ng bolt 3 Deformation or loss of bushing Replace 4 Unsuitability of maximum and or minimum length of damper strut and or shock absorber Replace with proper parts 5 Breakage of coil spring Replace 6 Wear or damage of ball joint Replace 7 Deformation of stabilizer clamp FS 26 Replace
15. nnect the ball joint to transverse link Tightening torque Castle nut 40 N m 4 1 kgf m 30 ft Ib 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 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 Ib loaded in direc tion shown in the figure measure the dimension 01 5 00035 2 With 686 70 kgf 154 Ib loaded in oppo site direction shown in the figure measure the dimension 0 2 FS 00036 3 Calculate plays from the following formula 4 When plays are larger than the following val ue 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 vi sually 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 FRONT STRUT FRONT SUSPENSION 5 Front Strut 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 adjust ing bolt which sec
16. rear bushing 2 Loosen the nut and remove rear bushing O gt H p FS 00032 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 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 Ib 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 dam age 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 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 Ib CAUTION Do not apply grease to tapered portion of ball stud 2 Co
17. 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 fac ing up 2 Move the piston rod to center of its entire stroke 3 While holding the piston rod end with finger tips 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 fac ing up 2 Fully extend the piston rod 3 With the piston rod fully extended place the piston rod side down The strut must stand ver tically 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 out lined 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 00042 1 Flat top side 2 Identification paint 3 Inclined bottom side 5 Set the coil spring correctly so
18. s 19 Frorit StabiliZgrz2 tede bte ete decet e edes ete eve dede 23 Front Crossmember eene nennen eren ss nasa seda sena 24 SUD Eram meto te eee ee Pere Dat eee 25 General Diagnostic 26 GENERAL DESCRIPTION FRONT SUSPENSION 1 General Description A SPECIFICATIONS Item Non turbo Camber Tolerance 0945 0925 Caster Reference 3 03 Toe in 0 3 mm 0 0 12 in Each toe angle 0 0 07 30 Kingpin angle Reference 13 12 Wheel arch height Tolerance mm 47 _9 gq in 437 mm 17 20 in Diameter of stabilizer 21mm 0 83 in Camber Tolerance 0 45 0 50 0 55 Toe in 2 3 mm 0 079 0 118 in Each toe angle 0 05 0 07 30 Thrust angle 0 30 Wheel arch height Tolerance 54 mm 9 o in 440 mm 17 32 in 435 mm 17 13 in Diameter of stabilizer 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 mid dle value of specification The other items indicated in the specification ta ble cannot be adjusted If the other items exceeds specifi
19. s Countermeasures 1 Permanent distortion or breakage of coil spring Replace 2 Unsmooth operation of damper strut and or shock absorber Replace 3 Installation of wrong strut and or shock absorber Replace with proper parts 4 Installation of wrong coil spring Replace with proper parts 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 Countermeasures 1 Breakage of coil spring Replace 2 Overinflation pressure of tire Adjust Adjust or replace the coil springs with new ones 4 Fault in operation of damper strut and or shock absorber Replace 3 Improper wheel arch height 5 Damage or deformation of strut mount and or shock absorber mount Replace 6 Unsuitable installation maximum and or minimum length of damper strut and or shock absorber Replace with proper parts 7 Deformation or damage of bushing Replace 8 Deformation or damage of helper in strut assembly and or shock absorber Replace 9 Oil leakage of damper strut and or shock absorber 3 NOISE Possible causes Replace Countermeasures 1 Wear or damage of damper strut and or shock absorber component parts Replace Retighten to the specified torque 2 Loosening of suspension link installi
20. ssmember and then extract the transverse link from crossmember Sete gem t cf WEES FS 00028 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 bush ing 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 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 Ib 2 Transverse link and crossmember Tightening torque 125 N m 12 7 kgf m 92 3 ft Ib 3 Transverse link rear bushing and body Tightening torque 100 N m 10 2 kgf m 74 ft Ib 6 Check the wheel alignment and adjust if neces sary FS 16 FRONT TRANSVERSE LINK C DISASSEMBLY 1 FRONT BUSHING Using the ST press the front bushing out of place ST 927680000 INSTALLER amp REMOVER SET FS 00031 2 REAR BUSHING 1 Scribe an aligning mark on the transverse link and
21. 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 FS 20 FRONT STRUT NOTE Ensure that upper spring seat is positioned as shown in the figure Vo 1 Outside of body FS 00044 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 Ib FS 00041 10 Loosen the coil spring carefully 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 2 kgf 4 Ib to threaded portion With the force of 20 N 2 kgf 4 Ib applied read dial gauge indication P4 Apply a force of 20 N 2 kgf 4 Ib in the opposite direction of W then read dial gauge indication Po
22. ures 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 6 Remove the three nuts securing strut mount to body FS 00039 B INSTALLATION 1 Install the strut mount at upper side of strut to body and then tighten with nuts Tightening torque 20 2 0 kgf m 14 5 ft lb 2 Position the aligning mark on camber adjust ment 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 3 4 kgf m 24 3 ft lb 4 Install the bolts which secure brake hose to strut Tightening torque 33 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 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
23. usting bolt LH clockwise Rotate camber adjusting bolt RH counterclockwise FS 00018 FS 00019 Toe in is decreased Rotate camber adjusting bolt LH counterclockwise Rotate camber adjusting bolt RH clockwise 3 Tighten a new self locking nut Tightening torque 100 N m 10 2 kgf m 74 ft Ib FS 00019 FS 13 FS 00018 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 WHI MC 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 di rection adjust the other rear wheel equally in toe out direction in order to make thrust angle adjust ment 3 When the right and left adjusting bolts are turned incrementally by one graduation in the same direc tion the thrust angle will change approx 16 L is almost equal to 12 mm 0 472 in Thrust angle 0 130 Wil 0 FS 00022
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