2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

FRONT SUSPENSION FS

REAR SUSPENSION RS

WHEEL AND TIRE SYSTEM WT

DIFFERENTIALS DI
This service manual has been prepared
to provide SUBARU service personnel
TRANSFER CASE TC
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. DRIVE SHAFT SYSTEM DS
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of ABS ABS
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual ABS (DIAGNOSTICS) ABS
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. BRAKE BR
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts. PARKING BRAKE PB

POWER ASSISTED SYSTEM PS

(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. G1830GE5

FRONT SUSPENSION

FS
Page
1. General Description ....................................................................................2
2. Wheel Alignment .........................................................................................8
3. Front Transverse Link ...............................................................................16
4. Front Ball Joint ..........................................................................................18
5. Front Strut .................................................................................................19
6. Front Stabilizer ..........................................................................................23
7. Front Crossmember ..................................................................................24
8. General Diagnostic Table..........................................................................25
 GENERAL DESCRIPTION
FRONT SUSPENSION

1. General Description
A: SPECIFICATIONS
1. STABILIZER
Model Bar dia.
ALL MODEL 20 mm (0.79 in)

2. WHEEL ALIGNMENT

Sedan Wagon
Model OUTBACK
Turbo Non-turbo Turbo Non-turbo
Camber (tolerance: ±0°45′) −0°25′ −0°15′ −0°20′ −0°10′ −0°05′
Caster (common difference: ±0°45′) 3°35′ 3°25′ 3°35′ 3°25′ 3°25′
0±3 mm (0±0.12 in)
Toe-in
Each toe angle: ±0°07′30”
Kingpin angle (tolerance: ±0°45′) 14°35′ 14°20′ 13°45′ 13°30′ 13°20′
Wheel arch height 396 mm 406 mm 387 mm 397 mm 402 mm
[tolerance: ±12 mm (±0.47 in)] (15.59 in) (15.98 in) (15.24 in) (15.63 in) (15.83 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 mid-
dle value of specification.
• The other items indicated in the specification ta-
ble cannot be adjusted. If the other items exceeds
specifications, check suspension parts and con-
nections 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

FS-3
 GENERAL DESCRIPTION
FRONT SUSPENSION

B: COMPONENT

SU0008

FS-4
 GENERAL DESCRIPTION
FRONT SUSPENSION

(1) Front crossmember (16) Jack-up plate (31) Boss

(2) Bolt ASSY (17) Dust seal
(3) Housing (18) Strut mount Tightening torque: N·m (kgf-m, ft-lb)
(4) Washer (19) Spacer T1: 20 (2.0, 14.5)
(5) Stopper rubber (Rear) (20) Upper spring seat T2: 25 (2.5, 18.1)
(6) Rear bushing (21) Rubber seat T3: 30 (3.1, 22)
(7) Stopper rubber (Front) (22) Dust cover T4: 40 (4.1, 30)
(8) Ball joint (23) Helper T5: 45 (4.6, 33)
(9) Transverse link (24) Coil spring T6: 50 (5.1, 37)
(10) Cotter pin (25) Damper strut T7: 55 (5.6, 41)
(11) Front bushing (26) Adjusting bolt T8: 100 (10.2, 74)
(12) Stabilizer link (27) Castle nut T9: 155 (15.8, 114)
(13) Clamp (28) Self-locking nut T10: 175 (17.8, 129)
(14) Bushing (29) Sub frame T11: 190 (19.4, 140)
(15) Stabilizer (30) Cover T12: 250 (25.5, 184)

FS-5
 GENERAL DESCRIPTION
FRONT SUSPENSION

C: CAUTION
• Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
• Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
• Keep the disassembled parts in order and pro-
tect them from dust or dirt.
• 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.
• Apply grease onto sliding or revolution surfaces
before installation.
• Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
• Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.

FS-6
 GENERAL DESCRIPTION
FRONT SUSPENSION

D: PREPARATION TOOL
1. SPECIAL TOOLS

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 & Used for replacing transverse link bushing.
REMOVER SET

B4M2385
927760000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET and shock mount.

B4M2384

2. GENERAL PURPOSE TOOLS

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-7
 WHEEL ALIGNMENT
FRONT SUSPENSION

2. Wheel Alignment
A: INSPECTION
Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure:

B4M1088A

FS-8
 WHEEL ALIGNMENT
FRONT SUSPENSION

1. WHEEL ARCH HEIGHT

1) Adjust tire pressure to specifications.
2) Set vehicle under “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, service
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.

Inner
Outer rear
Front fender rear quarter arch

Wheel arch height

Wheel arch height

A
A

A Cross-section
of arch
Front wheel arch height

Rear wheel arch height

Measuring
Wheel arch height

point
End of spindle

SU0009

Specified wheel arch height

Model
Turbo Non-turbo
Front 396±12 mm (15.59±0.47 in) 406±12 mm (15.98±0.47 in)
Sedan
Rear 376±12 mm (14.80±0.47 in) 381±12 mm (15.0±0.47 in)
Front 387±12 mm (15.24±0.47 in) 397±12 mm (15.63±0.47 in)
Wagon
Rear 376±12 mm (14.80±0.47 in) 381±12 mm (15.0±0.47 in)
Front — 402±12 mm (15.83±0.47 in)
OUTBACK
Rear — 386±12 mm (15.20±0.47 in)

FS-9
 WHEEL ALIGNMENT
FRONT SUSPENSION

2. CAMBER
• Inspection
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 in-
stall the wheel alignment gauge.
ST 927380002 ADAPTER

B4M0567B

(1) Alignment gauge

(2) Turning radius gauge S4M0300B

(1) Strut
NOTE:
(2) Adjusting bolt
Refer to the “SPECIFICATIONS” for the camber
values. (3) Housing
Front: <Ref. to FS-2, SPECIFICATIONS, General (4) Outer
Description.> (5) Inner
Rear: <Ref. to RS-2, SPECIFICATIONS, General (6) Camber is increased.
Description.> (7) Camber is decreased.
• Front camber adjustment
1) Loosen two self-locking nuts located at lower
front portion of strut.
CAUTION:
• When adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn
self-locking nut.
• Discard loosened self-locking nut and re-
place with a new one.
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′.

FS-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

Tightening torque: • Inspection
175 N·m (17.8 kgf-m, 129 ft-lb) 1) Using a toe gauge, measure front wheel toe-in.
3. CASTER Toe-in:
• Inspection 0±3 mm (0±0.12 in)
1) Place front wheel on turning radius gauge. Make 2) Mark rear sides of left and right tires at height
sure ground contacting surfaces of front and rear corresponding to center of spindles and measure
wheels are set at the same height. distance “A” between marks.
2) Set ST into the center of the wheel, and then in- 3) Move vehicle forward so that marks line up with
stall the wheel alignment gauge. front sides at height corresponding to center of
ST 927380002 ADAPTER 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

B4M0567B

(1) Alignment gauge

(2) Turning radius gauge
H4M1279B
NOTE: • Adjustment
Refer to the “SPECIFICATIONS” for the caster val-
ues. <Ref. to FS-2, SPECIFICATIONS, General 1) Loosen the left and right side steering tie-rods
Description.> lock nuts.

FS-11
 WHEEL ALIGNMENT
FRONT SUSPENSION

2) Turn the left and right tie rods equal amounts un- • Adjustment
til the toe-in is at the specification. 1) Loosen self-locking nut on inner side of link rear.
Both the left and right tie-rods are right-hand
threaded. To increase toe-in, turn both tie-rods CAUTION:
clockwise equal amounts (as viewed from the in- • When loosening or tightening adjusting bolt,
side of the vehicle). hold bolt head and turn self-locking nut.
• Discard loosened self-locking nut and re-
place with a new one.

S4M0348A

(1) Lock nut S4M0349A

3) Tighten tie-rod lock nut. (1) Adjusting bolt

Tightening torque: (2) Link rear
83 N·m (8.5 kgf-m, 61.5 ft-lb) 2) Turn adjusting bolt head until toe-in is at the
CAUTION: specification.
Correct tie-rod boot, if it is twisted.
NOTE:
Check the left and right wheel steering angle is
within specifications.
5. REAR WHEEL TOE-IN
• Inspection
1) Using a toe-in gauge, measure rear wheel toe-in.
Toe-in:
−1±2 mm (−0.039±0.079 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-12
 WHEEL ALIGNMENT
FRONT SUSPENSION

NOTE:
When left and right wheels are adjusted for toe-in at the same time, the movement of one scale graduation
changes toe-in by approximately 1.5 mm (0.12 in).

Left side Right side

Rotate counterclock-
Toe-in is increased. Rotate clockwise.
wise.

B4M0192 B4M0352

Rotate counterclock-
Toe-in is decreased. Rotate clockwise.
wise.

B4M0352 B4M0192

3) Tighten self-locking nut. • Adjustment

Tightening torque: Turn tie-rod to adjust steering angle of both inner
100 N·m (10.2 kgf-m, 74 ft-lb) and outer wheels.
6. STEERING ANGLE CAUTION:
• Check toe-in.
• Inspection • Correct boot if it is twisted.
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.
Steering angle:
Turbo and OUT-
Model Others
BACK
Inner wheel 34°30°±1.5° 37°20’±1.5°
Outer wheel 34°30°±1.5° 32°25’±1.5° S4M0348A

(1) Lock nut

FS-13
 WHEEL ALIGNMENT
FRONT SUSPENSION

7. THRUST ANGLE 3) When left and right adjusting bolts are turned in-
crementally by one graduation in the same direc-
• Inspection
tion, the thrust angle will change approximately 16′
1) Position vehicle on a level surface. [“L” is almost equal to 12 mm (0.472 in)].
2) Move vehicle 3 to 4 meters directly forward.
Thrust angle:
3) Determine locus of both front and rear axles.
0°±20 ′
4) Measure distance “L” between center line of loci
of the axles.
Thrust angle:
Less than 20 ′ when “L” is equal to or less
than 15 mm (59 in).

S4M0350B

(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)

NOTE:
S4M0350B
Thrust angle refers to a mean value of left and right
(1) Center line of loci (front axle) rear wheel toe angles in relation to vehicle body
(2) Center line of loci (rear axle) center line. Vehicle is driven straight in the thrust
angle direction while swinging in the oblique direc-
• Adjustment tion depending on the degree of the mean thrust
1) Make thrust angle adjustments by turning toe-in angle.
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.

B4M0193B

(1) Front
(2) Thrust angle
(3) Body center line

FS-14
 WHEEL ALIGNMENT
FRONT SUSPENSION

Thrust angle: r = (α − β)/2

α: Right rear wheel toe-in angle
β: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitute for α and β in the equation.

B4M0194B

(1) Front
(2) Body center line

FS-15
 FRONT TRANSVERSE LINK
FRONT SUSPENSION

3. Front Transverse Link NOTE:

These bolts should be tightened to such an extent
A: REMOVAL that they can still move back and forth in the oblong
1) Set the vehicle on the lift. shaped hole in the bracket (which holds the bush-
2) Disconnect ground terminal from battery. ing).
3) Lift-up the vehicle and remove the wheel. 2) Install bolts used to connect transverse link to
4) Remove sub frame. crossmember and temporarily tighten with nut.
5) Disconnect stabilizer link from transverse link. CAUTION:
6) Remove bolt securing ball joint of transverse link Discard loosened self-locking nut and replace
to housing. with a new one.
3) Insert ball joint into housing.
4) Connect stabilizer link to transverse link, and
temporarily tighten bolts.
CAUTION:
Discard loosened self-locking nut and replace
with a new one.

S4M0090
7) Remove nut (do not remove bolt.) securing
transverse link to crossmember.
8) Remove two bolts securing bushing bracket of
transverse link to vehicle body at rear bushing loca-
tion.

S4M0090
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:
Sedan Turbo model:
45 N·m (4.6 kgf-m, 33 ft-lb)
S4M0091 Except sedan Turbo model:
9) Extract ball joint from housing. 30 N·m (3.1 kgf-m, 22 ft-lb)
10) Remove bolt securing transverse link to cross- (2) Transverse link and crossmember
member and extract transverse link from cross-
member. Tightening torque:
100 N·m (10.2 kgf-m, 74 ft-lb)
(3) Transverse link rear bushing and body
Tightening torque:
250 N·m (25.5 kgf-m, 184 ft-lb)

SU0010

B: INSTALLATION
1) Temporarily tighten the two bolts used to secure
rear bushing of the transverse link to body.

FS-16
 FRONT TRANSVERSE LINK
FRONT SUSPENSION

NOTE: D: ASSEMBLY
• Move rear bushing back and forth until trans-
verse link-to-rear bushing clearance is established 1. FRONT BUSHING
(as indicated in figure.) before tightening. To reassemble, reverse disassembly procedures.
• Check wheel alignment and adjust if necessary.
CAUTION:
Install front bushing in correct direction, as
shown in figure.

S4M0352A

(1) Rear bushing

S4M0351A
C: DISASSEMBLY (1) Face bushing toward center of ball joint
1. FRONT BUSHING (2) Ball joint

Using ST, press front bushing out of place. 2. REAR BUSHING

ST 927680000 INSTALLER & REMOVER
SET 1) Install rear bushing to transverse link and align
aligning marks scribed on the two.
2) Tighten self-locking nut.
CAUTION:
• Discard loosened self-locking nut and re-
place with a new one.
• While holding rear bushing so as not to
change position of aligning marks, tighten self-
locking nut.
Tightening torque:
G4M0494 190 N·m (19.4 kgf-m, 140 ft-lb)
2. REAR BUSHING E: INSPECTION
1) Scribe an aligning mark on transverse link and 1) Check transverse link for wear, damage and
rear bushing. cracks, and correct or replace if defective.
2) Loosen nut and remove rear bushing. 2) Check bushings for cracks, fatigue or damage.
3) Check rear bushing for oil leaks.

G4M0495

FS-17
 FRONT BALL JOINT
FRONT SUSPENSION

4. Front Ball Joint C: INSPECTION

1) Measure play of ball joint by the following proce-
A: REMOVAL dures. Replace with a new one when the play ex-
1) Remove the wheel. ceeds the specified value.
2) Pull out the cotter pin from the ball stud, remove (1) With 686 N (70 kgf, 154 lb) loaded in the di-
the castle nut, and extract the ball stud from the rection shown in the figure, measure dimension
transverse link. 2 1.
3) Remove the bolt securing the ball joint to the
housing.

G4M0500
(2) With 686 N (70 kgf, 154 lb) loaded in the op-
G4M0499 posite direction shown in the figure, measure di-
4) Extract the ball joint from the housing. mension 22.
B: INSTALLATION
1) Install ball joint onto housing.
Torue (Bolt):
50 N·m (5.1 kgf-m, 37 ft-lb)
CAUTION:
Do not apply grease to tapered portion of ball
stud.
2) Connect ball joint to transverse link.
G4M0501
Torque (Castle nut): (3) Calculate plays from the following formula.
Sedan turbo model: S = 22 − 21
30 N·m (3.1 kgf-m, 22ft-lb) (4) When plays are larger than the following val-
Except sedan turbo model: ue, replace with a new one.
40 N·m (4.1 kgf-m, 30ft-lb)
FRONT BALL JOINT
3) Retighten castle nut further within 60° until a slot
in castle nut is aligned with the hole in ball stud Specified play for replacement: S
end, then insert new cotter pin and bend it around Less than 0.3 mm (0.012 in)
castle nut. 2) When play is smaller than the specified value, vi-
4) Install front wheel. sually inspect the dust cover.
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.
4) If the dust cover is damaged, replace with the
new ball joint.

FS-18
 FRONT STRUT
FRONT SUSPENSION

5. Front Strut 6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
1) Remove wheel.
2) Remove bolt securing brake hose from strut.

B4M1788
3) Scribe an alignment mark on the camber adjust-
ing bolt which secures strut to housing.
4) Remove bolt securing the ABS sensor harness.

SU0011

B4M1784
5) Remove two bolts securing housing to strut.
CAUTION:
While holding head of adjusting bolt, loosen
self-locking nut.

FS-19
 FRONT STRUT
FRONT SUSPENSION

B: INSTALLATION C: DISASSEMBLY
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) Position aligning mark on camber adjustment
bolt with aligning mark on lower side of strut.
CAUTION:
• While holding head of adjusting bolt, tighten
self-locking nut.
• Be sure to use new self-locking nut.
Tightening torque: S4M0095
175 N·m (17.8 kgf-m, 129 ft-lb) 2) Using ST, remove self-locking nut.
3) Install ABS sensor harness to strut. ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
4) Install bolts which secure brake hose to strut.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
5) Install wheels.
NOTE:
Check wheel alignment and adjust if necessary.
S4M0096A
3) Remove strut mount, upper spring seat and rub-
ber seat from strut.
4) Gradually decreasing compression force, and
remove coil spring.
5) Remove dust cover and helper spring.

FS-20
 FRONT STRUT
FRONT SUSPENSION

D: ASSEMBLY 5) Set the coil spring correctly so that its end face
1) Before installing coil spring, strut mount, etc., on fits well into the spring seat as shown.
the strut, check for the presence of air in the damp-
ening force generating mechanism of the strut
since air prevents proper dampening force from
being produced.
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod
facing up.
(2) Move the piston rod to the center of its entire
stroke.
(3) While holding the piston rod end with finger- S4M0353A
tips, move the rod up and down. 6) Install helper and dust cover to the piston rod.
(4) If the piston rod moves at least 10 mm (0.39 7) Pull the piston rod fully upward, and install rub-
in) in the former step, purge air from the strut. ber seat and spring seat.
3) Air purging procedure
NOTE:
(1) Place the strut vertically with the piston rod Ensure that upper spring seat is positioned as
facing up.
shown in figure.
(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 3 or 4 times from the first step.
NOTE:
After completely purging air from the strut, be sure
to place the strut with the 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”. S4M0097B
4) Using a coil spring compressor, compress the (1) Outside of body
coil spring.
NOTE: 8) Install strut mount to the piston rod, and tighten
Make sure that the vertical installing direction of coil the self-locking nut temporarily.
spring is as shown in figure. CAUTION:
Be sure to use a new self-locking nut.
9) Using hexagon wrench to prevent strut rod from
turning, tighten self-locking nut with ST.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
54 N·m (5.5 kgf-m, 39.8 ft-lb)

B4M0568B

(1) Flat (top side)

(2) Identification paint
(3) Inclined (bottom side)

S4M0096A
10) Loosen the coil spring carefully.

FS-21
 FRONT STRUT
FRONT SUSPENSION

E: INSPECTION F: DISPOSAL
Check the disassembled parts for cracks, damage CAUTION:
and wear, and replace with new parts if defective. • On struts which have “GAS FILLED” marked
1. DAMPER STRUT on outer housing under spring seat, completely
discharge gas before disposing, following the
1) Check for oil leakage. methods below.
2) Move the piston rod up and down to check it op- • Do not disassemble strut damper or place
erates smoothly without any binding. into a fire.
3) Play of piston rod • Drill holes before disposing of gas filled
• Measure the play as follows: struts.
Fix outer shell and fully extend the rod. Set a dial • Before handling gas filled struts, be sure to
gauge at the end of the rod: L [10 mm (0.39 in)], wear goggles to protect eyes from gas, oil and/
then apply a force of W [20 N (2 kgf, 4 lb)] to thread- or filings.
ed portion. With the force of 20 N (2 kgf, 4 lb) ap-
plied, read dial gauge indication: P1. Apply a force
of 20 N (2 kgf, 4 lb) in the opposite direction of “W”,
then read dial gauge indication: P2.

B4M1201
1) Place 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,
G4M0508 make holes in areas shown in the figure.
The free play is determined by the following equa-
tion:
Play = P1, P2
Limit of play:
Less than 0.8 mm (0.031 in)
If the play is greater, replace the strut.
2. STRUT MOUNT
Check rubber part for creep, cracks and deteriora-
tion, and replace it with new one if defective. B4M1202A

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 vehicle posture is uneven,
although there are no considerable reasons like
tire puncture, uneven loading, etc., check coil
spring for its free length referring to specifications,
cracks, etc., and replace it with a new one if defec-
tive.
5. HELPER
Replace it with new one if cracked or damaged.

FS-22
 FRONT STABILIZER
FRONT SUSPENSION

6. Front Stabilizer B: INSTALLATION

1) Install in the reverse order of removal.
A: REMOVAL NOTE:
1) Jack-up the front part of the vehicle and support
• Install bushing (on front crossmember side) while
it with safety stand (rigid racks).
aligning it with paint mark on stabilizer.
2) Remove jack-up plate from lower part of cross-
• Ensure that bushing and stabilizer have the
member.
same identification colors when installing.
3) Remove sub frame.
4) Remove bolts which secure stabilizer to cross-
member.

SU0012

(1) Mark stamped on stabilizer

B4M1846
(2) Bushing identification color
5) Remove bolts which secure stabilizer link to front
transverse link. 2) Always tighten rubber bushing location when
wheels are in full contact with the ground and ve-
hicle is curb weight.
Tightening torque (Sedan turbo model):
Jack-up plate to crossmember:
20 N·m (2.0 kgf-m, 14.5 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)
S4M0355
Tightening torque (Except sedan turbo model):
Jack-up plate to crossmember:
20 N·m (2.0 kgf-m, 14.5 ft-lb)
Stabilizer link to front transverse link:
30 N·m (3.1 kgf-m, 22 ft-lb)
Stabilizer to crossmember:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check bushing for cracks, fatigue or damage.
2) Check stabilizer link for deformities, cracks, or
damage, and bushing for protrusions from the hole
of stabilizer link.

FS-23
 FRONT CROSSMEMBER
FRONT SUSPENSION

7. Front Crossmember B: INSTALLATION

1) Install in the reverse order of removal.
A: REMOVAL
CAUTION:
1) Disconnect ground terminal from battery.
Always tighten rubber bushing when wheels
2) Lift-up vehicle and remove front tires and are in full contact with the ground and vehicle
wheels. is curb weight.
3) Remove sub frame.
4) Remove both stabilizer and jack-up plate. 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)
S4M0534A Crossmember to body:
(1) Front stabilizer 100 N·m (10.2 kgf-m, 74 ft-lb)
(2) Front crossmember 2) Purge air from power steering system.
NOTE:
5) Disconnect tie-rod end from housing.
Check wheel alignment and adjust if necessary.
6) Remove front exhaust pipe.
7) Remove front transverse link from front cross- C: INSPECTION
member and body. Check crossmember for wear, damage and cracks,
and correct or replace if defective.

SU0010
8) Remove nuts attaching engine mount cushion
rubber to crossmember.
9) Remove steering universal joint.
10) Disconnect power steering pipe from steering
gear box.
11) Lift engine by approx. 10 mm (0.39 in) by using
chain block.
12) Support crossmember with a jack, remove nuts
securing crossmember to body and lower cross-
member gradually along with steering gearbox.
CAUTION:
When removing crossmember downward, be
careful that tie-rod end does not interfere with
SFJ boot.

FS-24
 GENERAL DIAGNOSTIC TABLE
FRONT SUSPENSION

8. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IM-
PROPER WHEEL ARCH HEIGHT

Possible causes 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 2) Rocking of vehicle continues too long after run-
ning over bump and/or hump.
1) Large rebound shock
3) Large shock in bumping

Possible causes Countermeasures

(1) Breakage of coil spring Replace.
(2) Overinflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace coil springs with new ones.
(4) Fault in operation of damper strut and/or shock absorber Replace.
(5) Damage or deformation of strut mount and/or shock absorber mount Replace.
(6) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly and/or shock Replace.
absorber
(9) Oil leakage of damper strut and/or shock absorber Replace.

3. NOISE

Possible causes Countermeasures

(1) Wear or damage of damper strut and/or shock absorber component Replace.
parts
(2) Loosening of suspension link installing bolt Retighten to the specified torque.
(3) Deformation or loss of bushing Replace.
(4) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(5) Breakage of coil spring Replace.
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.

FS-25
 GENERAL DIAGNOSTIC TABLE
FRONT SUSPENSION

FS-26