FRONT SUSPENSION
FS
  1. General Description
  2. Wheel Alignment
  3. Crossmember Support
  4. Stabilizer
  5. Ball Joint
  6. Front Arm
  7. Crossmember
  8. Front Strut
  9. General Diagnostic Table
FRONT SUSPENSION > General Description　
SPECIFICATION
1. FRONT ALIGNMENT (INSPECTION VALUE)

Suspension height

64 (2.52)

(Tolerance: +12 mm−24 mm (+0.47in−0.94in))

mm (in)

Camber (tolerance: ±0°30′ Differences between RH and LH: 35′ or less)

−0°05′

Caster (referential value)

5°22′

Steering angle (tolerance: ±1.5°)

Inner wheel

38.4°

Outer wheel

33.5°

Toe-in

mm (in)

0±3 (0±0.12) Toe angle (sum of both wheels): 0°±0°15′

Kingpin angle (referential value)

13°31′
2. REAR ALIGNMENT (INSPECTION VALUE)

Suspension height

−73 (−2.87)

(Tolerance: +12 mm−24 mm (+0.47in−0.94in))

mm (in)

Camber (tolerance: ±0°45′ Differences between RH and LH: 45′ or less)

−0°50′

Toe-in

mm (in)

IN3±3 (IN0.12±0.12)

Toe angle (sum of both wheels): IN0°15′±15′

Thrust angle (tolerance: 0°00′±30′)

0°00′
 

  • Adjust with the value less than the inspection value, taking aging variation into consideration.

  • Front toe-in, rear toe-in and front camber can be adjusted. Adjust if the value of toe-in or camber exceeds the tolerance range of the specification chart.

  • Other items except for front toe-in, rear toe-in and front camber that are described in the specification chart cannot be adjusted.

  • If other items exceed the tolerance range of the specification chart, check the suspension parts and connections for deformation. If defective, replace them with new parts.

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

α = Individual toe angles

FRONT SUSPENSION > General Description　
COMPONENT
1. FRONT SUSPENSION

(1)

Spacer crossmember front

(15)

Stud bolt∗

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Crossmember COMPL front

(16)

Bushing rear front arm

T1:

25 (2.5, 18.4)

(3)

Flange bolt

(17)

Bushing arm front

T2:

39 (4.0, 28.8)

(4)

Self-locking nut A

(18)

Arm COMPL front

T3:

50 (5.1, 36.9)

(5)

Stiffener

(19)

Ball joint COMPL

T4:

60 (6.1, 44.3)

(6)

Bolt

(20)

Castle nut

T5:

70 (7.1, 51.6)

(7)

Crossmember support front

(21)

Cotter pin

T6:

95 (9.7, 70.1)

(8)

Stabilizer front

(22)

Front arm rear plate

T7:

110 (11.2, 81.1)

(9)

Bushing stabilizer front

(23)

Self-locking nut B

T8:

150 (15.3, 110.6)

(10)

Clamp stabilizer

(24)

Strut ASSY

T9:

155 (15.8, 114.3)

(11)

Flange nut

(25)

Adjusting bolt

(12)

Stabilizer link front

(26)

Adjusting washer

(13)

Crossmember support rear

(27)

Front axle housing

(14)

Stopper arm front

∗: Cannot be reused if the stud bolt is removed from the vehicle.
2. FRONT STRUT

(1)

Dust seal

(6)

Dust cover front

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Self-locking nut

(7)

Coil spring front

T1:

32 (3.3, 23.6)

(3)

Flange nut

(8)

Helper front

T2:

55 (5.6, 40.6)

(4)

Mount strut front

(9)

Rubber seat LWR

(5)

Mount bearing front

(10)

Strut COMPL front
FRONT SUSPENSION > General Description　
CAUTION
FRONT SUSPENSION > General Description　
PREPARATION TOOL
1. SPECIAL TOOL

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

18360AA040

HANGER

  • Used for removing and installing engine.

  • Used for removing and installing rocker cover.

  • Used together with BOLT (18363AA050).

18363AA050

BOLT

  • Used for removing and installing engine.

  • Used for removing and installing rocker cover.

  • Used together with HANGER (18360AA040).

20399AG000

STRUT MOUNT SOCKET

  • Used for disassembling and assembling strut assembly and shock absorber assembly rear.

  • Used for checking center nut torque of strut assembly and shock absorber assembly rear.

927680000

INSTALLER & REMOVER SET

Used for replacing the bushing arm front of the arm COMPL front.

20299AG000

REMOVER

  • Used for replacing the bushing rear front arm of the arm COMPL front.

  • Used together with BASE (20299AG010).

20299AG010

BASE

  • Used for replacing the bushing rear front arm of the arm COMPL front.

  • Used together with REMOVER (20299AG000).

20299AG020

STUD BOLT SOCKET

Used for removing and installing the stud bolt for installing portion of the arm COMPL front.

—

SUBARU SELECT MONITOR 4

Used for setting of each function and troubleshooting for electrical system.

 

For detailed operation procedures, refer to “Help” of application.
2. GENERAL TOOL

TOOL NAME

REMARKS

Alignment gauge

Used for measuring wheel alignment.

Alignment gauge adapter

Used for measuring wheel alignment.

Coil spring compressor

Used for disassembling and assembling strut assembly and shock absorber assembly rear.

Shackle

  • Two units used for hanging power unit.

  • Attached to both end of chain sling and connected to engine hook.

  • Load capacity: 250 kg (551 lb) or more

Sling belt

  • Used for removing and installing the crossmember COMPL front.

  • Width: 35 — 40 mm (1.38—1.57in)

  • Length: 2 m (6.6ft)

  • Load capacity: 1 t (2205 lb) or more

Wire rope

  • Used for connecting the shackle to hang power unit.

  • Load capacity: 250 kg (551 lb) or more

Ball joint puller

Used for disconnecting tie-rod end.

Dial gauge

Used for measuring the strut COMPL front.

Magnet stand

Used for measuring the strut COMPL front.

Turning radius gauge

Used for measuring wheel alignment.

Toe-in gauge

Used for toe-in measurement.

DST-i

Used together with Subaru Select Monitor 4.
FRONT SUSPENSION > Wheel Alignment　
INSPECTION

Check the following items before performing the wheel alignment measurement.

Check, adjust and measure the wheel alignment in accordance with the following procedures.

1

Suspension height (front and rear wheels)

Inspection: FRONT SUSPENSION>Wheel Alignment>INSPECTION > SUSPENSION HEIGHT

↓

2

Camber (front wheel)

Inspection: FRONT SUSPENSION>Wheel Alignment>INSPECTION > CAMBER

Adjustment: FRONT SUSPENSION>Wheel Alignment>ADJUSTMENT > FRONT CAMBER

Camber (rear wheel)

Inspection: FRONT SUSPENSION>Wheel Alignment>INSPECTION > CAMBER

 

Rear camber cannot be adjusted. If the value exceeds the difference range between right and left, check the suspension parts and connections for deformation. If defective, replace with new parts.

↓

3

Caster (front wheel)

Inspection: FRONT SUSPENSION>Wheel Alignment>INSPECTION > CASTER

↓

4

Adjustment of difference between right and left steering angles

Inspection: FRONT SUSPENSION>Wheel Alignment>INSPECTION > STEERING ANGLE

Adjustment: FRONT SUSPENSION>Wheel Alignment>ADJUSTMENT > ADJUSTMENT OF DIFFERENCE BETWEEN RIGHT AND LEFT STEERING ANGLES

↓

5

Front toe-in

Inspection: FRONT SUSPENSION>Wheel Alignment>INSPECTION > FRONT TOE-IN

Adjustment: FRONT SUSPENSION>Wheel Alignment>ADJUSTMENT > FRONT TOE-IN

↓

6

Rear toe-in

Inspection: FRONT SUSPENSION>Wheel Alignment>INSPECTION > REAR TOE-IN

Adjustment: FRONT SUSPENSION>Wheel Alignment>ADJUSTMENT > REAR TOE-IN

↓

7

Thrust angle

Inspection: FRONT SUSPENSION>Wheel Alignment>INSPECTION > THRUST ANGLE

Adjustment: FRONT SUSPENSION>Wheel Alignment>ADJUSTMENT > THRUST ANGLE
1. SUSPENSION HEIGHT
1.

Park the vehicle on a level surface.

2.

Empty the vehicle so that it is at “curb weight”.

 

Empty the luggage room, load the spare tire, jack and service tools, and fill up the fuel tank.

3.

Set the steering wheel in a straight-ahead position, and stabilize the suspension by moving the vehicle in a straight line for 5 m (16 ft) or more.

4.

Measure the distance (d) from the spindle end (c) to the ground surface.

5.

Measure the distances (e) from the end of mounting bolt for the front arm rear plate (point “A” shown in the following figure) and from the end of bolt for the sub frame assembly rear at rear (point “B” shown in the following figure) to the ground surface.

Calculate the suspension heights (a) and (b) using the following calculation:

(d) − (e) = suspension height

Suspension height specification mm (in)

(Tolerance: +12 mm−24 mm (+0.47in−0.94in))

Front

Rear

64 (2.52)

−73 (−2.87)
2. CAMBER
1.

Place the tires on the turning radius gauge.

 

Make sure that the ground contact surfaces of the front tires and rear tires are at the same level.

2.

Set the adapter into the center of wheel, and then set the wheel alignment gauge.

(a)

Alignment gauge

(b)

Turning radius gauge

(c)

Adapter
3.

Measure the camber angle in accordance with the operation manual for wheel alignment gauge.

Front camber (difference between RH and LH 45′ or less)

Rear camber (difference between RH and LH 45′ or less)

−0°05′±0°45′

−0°50′±0°45′
3. CASTER
1.

Place the front tires on the turning radius gauge.

 

Make sure that the ground contact surfaces of the front tires and rear tires are at the same level.

2.

Set the adapter into the center of wheel, and then set the wheel alignment gauge.

(a)

Alignment gauge

(b)

Turning radius gauge

(c)

Adapter
3.

Measure the caster angle in accordance with the operation manual for wheel alignment gauge.

Caster

5°22′
4. STEERING ANGLE
1.

Place the vehicle on turning radius gauge.

2.

While depressing the brake pedal, turn the steering wheel fully to the left and right.

3.

With the steering wheel held at each fully turned position, measure both the inner and outer wheel steering angles.

Inner wheel

Outer wheel

38.4°

33.5°
5. FRONT TOE-IN

Toe-in: Inspection value

0±3 mm (0±0.12in)

1.

Set the toe-in gauge in the position at wheel axis center height behind the right and left front tires.

2.

Place a mark at the center of both left and right tires, and measure distance “A” between the marks.

3.

Move the vehicle forward to rotate the tires 180°.

 

Be sure to rotate the tires in the forward direction.

4.

Measure the distance “B” between the left and right marks.

Find toe-in using the following calculation:

A − B = Toe-in

6. REAR TOE-IN

Refer to the FRONT TOE-IN for rear toe-in inspection procedures. FRONT SUSPENSION>Wheel Alignment>INSPECTION > FRONT TOE-IN

Toe-in: Inspection value

3±3 mm (0.12±0.12in)

7. THRUST ANGLE
1.

Park the vehicle on a level surface.

2.

Move the vehicle 3 — 4 meters (10 — 13 ft) straight forward.

3.

Draw the center of loci for both the front and rear axles.

4.

Measure distance “L” between the center lines of the axle loci.

Thrust angle: Inspection value

0°00′±30′

Less than 30′ when “L” is 23 mm (0.9in) or less.

(a)

Center line of loci (front axle)

(b)

Center line of loci (rear axle)
FRONT SUSPENSION > Wheel Alignment　
ADJUSTMENT
 

When the wheel alignment has been adjusted, perform the following adjustment.

1. FRONT CAMBER
1.

Adjust the camber angle to the following value.

Camber (difference between RH and LH 35′ or less)

−0°05′±0°30′
2.

Loosen the nut side, while holding the strut assembly bolt side. (2 places at upper and lower)

3.

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

 

Moving the adjusting bolt by one scale changes the camber by approximately 0°10′.

(a)

Strut ASSY

(d)

Outer direction

(g)

Camber is decreased.

(b)

Adjusting bolt

(e)

Inner direction

(c)

Front axle housing

(f)

Camber is increased.

To increase camber.

Rotate the left side counterclockwise.

Rotate the right side clockwise.

To decrease camber.

Rotate the left side clockwise.

Rotate the right side counterclockwise.
4.

Tighten two new flange nuts.

 

While holding the bolt side, tighten the nut to the specified torque.

 

First, tighten the adjusting bolt (upper side) to the specified torque.

Tightening torque:

155 N·m (15.8kgf-m, 114.3ft-lb)

2. ADJUSTMENT OF DIFFERENCE BETWEEN RIGHT AND LEFT STEERING ANGLES
1.

Operate the steering system from lock to lock and stop operating it at the center position from lock to lock, and then install the steering wheel in the straight-ahead position.

 

Using of the steering wheel angle sensor output values shown on Subaru Select Monitor will facilitate your work.

2.

Before adjusting toe-in, be sure to adjust the steering wheel in the straight-ahead position (steering angle sensor output: 0 deg).

3. FRONT TOE-IN

When adjusting the toe-in, adjust it to the following value.

Toe-in: Adjustment value

0±2 mm (0±0.08in)

1.

Check that the left and right wheel steering angles are within specification.

2.

Loosen the tie-rod end lock nuts on the left and right sides.

3.

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

 

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

4.

Tighten the tie-rod end lock nut.

Tightening torque:

85 N·m (8.7kgf-m, 62.7ft-lb)

5.

Correct the boot steering gearbox if it is twisted.

4. REAR TOE-IN

When adjusting, adjust it to the following value.

Toe-in: Adjustment value

3±2 mm (0.12±0.08in)

1.

Loosen the self-locking nut while holding the bolt side of rear lateral link assembly front.

2.

Turn the adjusting bolt until toe-in is within the specification.

 

When the left and right wheels are adjusted for toe-in at the same time, the movement of one scale graduation changes toe-in by approx. 6 mm (0.24in).

To increase toe-in.

Rotate the left side clockwise.

Rotate the right side counterclockwise.

To decrease toe-in.

Rotate the left side counterclockwise.

Rotate the right side clockwise.
3.

Attach and tighten a new self-locking nut.

Tightening torque:

100 N·m (10.2kgf-m, 73.8ft-lb)

 

While holding the bolt side, tighten the nut to the specified torque.

5. THRUST ANGLE

When adjusting, adjust it to the following value.

Thrust angle: Adjustment value

0°00′±20′

Less than 20′ when “L” is 15 mm (0.6in) or less.

(a)

Center line of loci (front axle)

(b)

Center line of loci (rear axle)
1.

Make thrust angle adjustments by turning the toe-in adjusting bolts of the rear suspension equally in the same direction.

2.

When one rear tire is adjusted in a toe-in direction, adjust the other rear tire equally in a toe-out direction, in order to make the thrust angle adjustment.

3.

When the left and right adjusting bolts are turned by one graduation, the thrust angle will change approx. 15′. (“L” is approx. 11 mm (0.43in).)

 

Thrust angle is a mean value of left and right wheel toe angles in relation to the vehicle body center line.

Vehicle is driven straight in the thrust angle direction while slanting in the oblique direction depending on the degree of the mean thrust angle.

(a)

Thrust angle

(b)

Body center line

Thrust angle:

γ = (α − β)/2

α: Rear RH toe-in angle

β: Rear LH toe-in angle

Substitute only the positive toe-in values from each tire into α and β in the calculation.

(a)

Front

(b)

Body center line
FRONT SUSPENSION > Crossmember Support　
REMOVAL
1.

Lift up the vehicle.

2.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

3.

Remove the bolt, and remove the crossmember support rear.

4.

Remove the bolt, and remove the crossmember support front.

FRONT SUSPENSION > Crossmember Support　
INSTALLATION
1.

Install the crossmember support front and the crossmember support rear.

Tightening torque:

Crossmember support front: 60 N·m (6.1kgf-m, 44.3ft-lb)

Crossmember support rear: 70 N·m (7.1kgf-m, 51.6ft-lb)

2.

Install the under cover front.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

FRONT SUSPENSION > Stabilizer　
REMOVAL
1. STABILIZER LINK
1.

Lift up the vehicle, and then remove the front wheels.

2.

Remove the stabilizer link front on the left and right sides.

2. STABILIZER BUSHING
1.

Lift up the vehicle.

2.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

3.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

4.

Remove the clamp stabilizer on the left and right sides.

5.

Remove the bushing stabilizer front.

3. STABILIZER
1.

Lift up the vehicle.

2.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

3.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

4.

Disconnect the stabilizer link front (bottom part) on the left and right sides.

5.

Remove the clamp stabilizer on the left and right sides, and remove the bushing stabilizer front.

6.

Remove the stabilizer front.

FRONT SUSPENSION > Stabilizer　
INSTALLATION
 

  • For parts which are not reusable, always use new parts.

  • Always tighten the bushing stabilizer front in the state where the vehicle is at curb weight and the wheels are in full contact with the ground.

  • Install the clamp stabilizer with the peak of triangle facing the front of the vehicle.

1. STABILIZER LINK
1.

Before installation, inspect the following items and replace any faulty part with a new one.

Check the stabilizer link front for damage.

2.

Install the stabilizer link front.

Tightening torque:

60 N·m (6.1kgf-m, 44.3ft-lb)

3.

Lower the vehicle, and install the front wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

2. STABILIZER BUSHING
1.

Before installation, inspect the following items and replace any faulty part with a new one.

Check the bushing stabilizer front for abnormal cracks, fatigue or damage.

2.

Install the bushing stabilizer front.

3.

Install the clamp stabilizer.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

4.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

5.

Install the under cover front.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

3. STABILIZER
1.

Install the clamp stabilizer.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

2.

Install the stabilizer link front (bottom part).

Tightening torque:

60 N·m (6.1kgf-m, 44.3ft-lb)

3.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

4.

Install the under cover front.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

FRONT SUSPENSION > Ball Joint　
REMOVAL
1.

Lift up the vehicle, and then remove the front wheels.

2.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

3.

Remove the ball joint COMPL.

 

Be careful not to damage the boot of the ball joint.

(1)

Remove the cotter pin (a).

(2)

Remove the castle nut (b).

(3)

Use a ball joint puller (c) to detach the arm COMPL front (d).

Preparation tool:

Ball joint puller

(4)

Remove the bolt and pull out the ball joint COMPL.

FRONT SUSPENSION > Ball Joint　
INSTALLATION
 

For parts which are not reusable, always use new parts.

1.

Install the ball joint COMPL to the front axle housing.

 

  • Do not apply grease to the tapered portion of ball stud.

  • Be careful not to damage the boot of the ball joint.

  • Before tightening, make sure the bottom surface of front axle housing and stepped section of ball joint COMPL are in contact.

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

(a)

Bottom surface of front axle housing

(b)

Stepped section of ball joint COMPL

(c)

Front axle housing

(d)

Ball joint COMPL
2.

Install the ball joint COMPL into the arm COMPL front.

(1)

Connect the ball joint COMPL to the arm COMPL front.

 

If the ball stud hole and the cutout portion of the castle nut are not aligned after tightening, tighten the castle nut within the range of 60° to align with each other.

Tightening torque:

39 N·m (4.0kgf-m, 28.8ft-lb)

(2)

Install a new cotter pin.

3.

Install the under cover front.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

4.

Lower the vehicle, and install the front wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

FRONT SUSPENSION > Ball Joint　
INSPECTION
1.

Check that there is no looseness by moving the upper and lower portions of front tire in an axial direction with the brake pedal depressed.

2.

Check that there is no looseness by moving the upper and lower portions of front tire in an axial direction with the brake pedal released.

3.

Replace the ball joint COMPL if the boot is damaged when visually inspecting the boot.

FRONT SUSPENSION > Front Arm　
REMOVAL
1.

Lift up the vehicle, and then remove the front wheels.

2.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

3.

Remove the crossmember support rear. FRONT SUSPENSION>Crossmember Support>REMOVAL

4.

Remove the arm COMPL front.

 

Be careful not to damage the boot of the ball joint.

(1)

Remove the bolt from the front axle housing.

(2)

Lower the arm COMPL front, and remove the ball joint portion from the front axle housing.

(3)

Remove the front arm rear plate.

(4)

Remove the arm COMPL front.

FRONT SUSPENSION > Front Arm　
INSTALLATION
 

For parts which are not reusable, always use new parts.

1.

Before installation, inspect the following items and replace any faulty part with a new one.

  • Check the arm COMPL front for damage or cracks, and replace if defective.

  • Visually check the bushing for abnormal cracks, fatigue or damage.

  • Visually check the boot on the ball joint for damage.

2.

Using new self-locking nuts and flange bolts, temporarily tighten the arm COMPL front to the crossmember COMPL front.

3.

Using new self-locking nuts, temporarily tighten the bushing rear front arm connecting area of the arm COMPL front to the body side together with the front arm rear plate.

4.

Install the front arm rear plate using new flange bolts.

Tightening torque:

150 N·m (15.3kgf-m, 110.6ft-lb)

5.

Install the ball joint section to the front axle housing.

 

  • Be careful not to damage the boot of the ball joint.

  • Before tightening, make sure the bottom surface of front axle housing and stepped section of ball joint COMPL are in contact.

Tightening torque:

50 N·m (5.1kgf-m, 36.9ft-lb)

(a)

Bottom surface of front axle housing

(b)

Stepped section of ball joint COMPL

(c)

Front axle housing

(d)

Ball joint COMPL
6.

Install the crossmember support rear.

Tightening torque:

70 N·m (7.1kgf-m, 51.6ft-lb)

7.

Install the under cover front.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

8.

Install the front wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

9.

Unload the vehicle from the lift, confirm that the wheels are in full contact with the ground and the vehicle is at curb weight, and tighten the bolt which secures the arm COMPL front to the crossmember COMPL front, and the nut which secures the COMPL to the body side.

Tightening torque:

Refer to “COMPONENT” of “General Description” for the tightening torque. FRONT SUSPENSION>General Description>COMPONENT > FRONT SUSPENSION

10.

Inspect the wheel alignment and adjust if necessary.

11.

Perform the following adjustments using Subaru Select Monitor.

FRONT SUSPENSION > Front Arm　
DISASSEMBLY
1. BUSHING ARM FRONT
1.

Put an alignment mark on the arm COMPL front based on the gap of bushing intermediate plate for the bushing arm front.

 

Always put an alignment mark for aligning the position on bushing installation.

(a)

Put an alignment mark.

(b)

Gap of bushing intermediate plate

(c)

Bushing intermediate plate
2.

Using the ST and a press, remove the bushing arm front.

Preparation tool:

ST: INSTALLER & REMOVER SET (927680000)

2. BUSHING REAR FRONT ARM
1.

Put an alignment mark on arm COMPL front based on the center of recess portion of the busing rear front arm.

2.

Using the ST and a press, remove the busing rear front arm.

Preparation tool:

ST1: REMOVER (20299AG000)

ST2: BASE (20299AG010)

(a)

Press

(b)

Arm COMPL front

(c)

Bushing rear front arm
FRONT SUSPENSION > Front Arm　
ASSEMBLY
1. BUSHING ARM FRONT
1.

Before assembly, inspect the following items and replace any faulty part with a new one.

  • Check the arm COMPL front for damage or cracks, and replace if defective.

  • Visually check the bushing for abnormal cracks, fatigue or damage.

  • Visually check the boot on the ball joint COMPL for damage.

2.

Match the alignment marks on the gap of bushing intermediate plate for the bushing arm front and on the arm COMPL front.

3.

Using the ST and a press, install the bushing arm front.

Preparation tool:

ST: INSTALLER & REMOVER SET (927680000)

2. BUSHING REAR FRONT ARM
1.

Before installation, inspect the following items and replace any faulty part with a new one.

  • Check the arm COMPL front for damage or cracks, and replace if defective.

  • Visually check the bushing for abnormal cracks, fatigue or damage.

  • Visually check the boot on the ball joint COMPL for damage.

2.

Align a line extending from the center of recess portion with the ball joint after placing the protrusion (A) of recess portion to the ball joint side of the arm COMPL front.

(a)

Recess section

(b)

Center line of recess section
3.

Using the ST and a press, install the busing rear front arm.

 

  • Align the upper face of arm COMPL front and the end of bushing during installation.

  • Install so that the upper exposed length (a) of the bushing inner cylinder becomes longer than the lower exposed length (b).

(a)

Exposed length of inner cylinder (upper)

(b)

Exposed length of inner cylinder (lower)

(c)

Aligned

(d)

Not aligned

Preparation tool:

ST1: REMOVER (20299AG000)

ST2: BASE (20299AG010)

(a)

Press

(b)

Arm COMPL front

(c)

Bushing rear front arm
FRONT SUSPENSION > Crossmember　
REMOVAL
 

  • The power steering control module continues to operate after the engine stops and calculates the temperature in the control module. Therefore, before starting service of the power steering system which requires disconnection of the connector, stop the engine and allow approx. 30 minutes until the control module becomes cold.

  • Be careful not to let any foreign matter (dust, water, oil, etc.) enter into the power steering control module connector when removing or installing. If a foreign matter enters, completely remove it.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>DISASSEMBLY

3.

Fully open the front hood. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

4.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

5.

Remove the clip from the air intake boot, and loosen the clamp.

6.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

 

Be careful not to pull out the PCV hose.

7.

Remove the air cleaner case. INTAKE (INDUCTION)(H4DO)>Air Cleaner Case>REMOVAL

8.

Disconnect the power steering harness connector and remove the harness clamp.

9.

Lift up the vehicle, and then remove the front wheels.

10.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

11.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

12.

Remove the nuts which secure the engine mounting to the crossmember.

13.

Lower the vehicle.

14.

Remove the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>REMOVAL > PITCHING STOPPER

15.

Using the ST1, install the ST2 to the engine unit.

Preparation tool:

ST1: BOLT (18363AA050)

ST2: HANGER (18360AA040)

Tightening torque:

43 N·m (4.4kgf-m, 31.7 ft-lb)

16.

Support the engine with a lifting device and wire ropes.

(1)

While lifting up the vehicle, also raise up the lifting device simultaneously.

 

Be careful not to damage the vehicle with a lifting device or wire ropes.

(2)

Raise up the lifting device, and lift the engine body by approx. 10 mm (0.39in).

(3)

Attach the sling belt so that it wraps around the both frames using the shackle.

 

  • Be sure to attach the sling belt to ensure safety in operation.

  • Use a sling belt with the length of 2 m (6.6ft), the width of 35 — 40 mm (1.38 — 1.57in) and the load capacity of 1 t (2205 lb) or more.

  • Use a shackle with the load capacity of 0.5 t (1103 lb) or more.

Preparation tool:

Wire rope

Sling belt

Shackle

17.

Remove the crossmember support rear and the crossmember support front. FRONT SUSPENSION>Crossmember Support>REMOVAL

18.

Remove the stabilizers. FRONT SUSPENSION>Stabilizer>REMOVAL > STABILIZER

19.

Disconnect the tie-rod end.

 

Be careful not to damage the boot of the ball joint.

(1)

Remove the cotter pin (a).

(2)

Remove the castle nut (b).

(3)

Using a ball joint puller (d), remove the tie-rod end (c).

Preparation tool:

Ball joint puller

20.

Remove the arm COMPL front. FRONT SUSPENSION>Front Arm>REMOVAL

21.

Remove the universal joint assembly steering. POWER ASSISTED SYSTEM (POWER STEERING)>Universal Joint>REMOVAL

22.

Remove the steering gearbox assembly from the crossmember COMPL front.

 

When lowering the transmission jack, make sure that the tie-rod end and the drive shaft boot do not interfere. The drive shaft boot may be damaged.

(1)

Support the steering gearbox assembly from the bottom side using a transmission jack.

(2)

Remove the bolts securing the steering gearbox assembly and stiffener to the crossmember COMPL front.

(3)

Lower the transmission jack slowly, and lower the steering gearbox assembly.

23.

Remove the crossmember COMPL front.

 

The crossmember COMPL is heavy. Make sure that it is firmly supported so that it is level.

(1)

Support the crossmember COMPL front from the bottom side using a transmission jack.

(2)

Remove the bolts which secure the crossmember COMPL front to the body.

(3)

Lower the transmission jack slowly, and lower the crossmember COMPL front.

FRONT SUSPENSION > Crossmember　
INSTALLATION
 

  • When raising the transmission jack, make sure that the tie-rod end and the drive shaft boot do not interfere. The drive shaft boot may be damaged.

  • The crossmember COMPL front is heavy. Make sure that it is firmly supported so that it is level.

  • For parts which are not reusable, always use new parts.

  • Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground.

  • Install the clamp stabilizer bushing with the peak of triangle facing the front of the vehicle.

1.

Install the crossmember COMPL front.

 

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

(1)

Install the bolts which secure the crossmember COMPL front to the body.

Tightening torque:

Refer to “COMPONENT” of “General Description” for the tightening torque. FRONT SUSPENSION>General Description>COMPONENT > FRONT SUSPENSION

2.

Lower the engine and remove the lifting device and wire ropes.

3.

Remove the ST1 and ST2 from the engine unit.

4.

Install the engine mounting and the crossmember COMPL front with new nuts.

Tightening torque:

Engine mounting — crossmember COMPL front: 90 N·m (9.2kgf-m, 66.4ft-lb)

5.

Install the pitching stopper. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Mounting System>INSTALLATION > PITCHING STOPPER

6.

Install the steering gearbox assembly and stiffener to the crossmember COMPL front.

Tightening torque:

Refer to “COMPONENT” of “General Description” for the tightening torque. FRONT SUSPENSION>General Description>COMPONENT > FRONT SUSPENSION

7.

Connect the power steering harness connector and install the harness clamp.

8.

Install the universal joint assembly steering. POWER ASSISTED SYSTEM (POWER STEERING)>Universal Joint>INSTALLATION

9.

Install the arm COMPL front. FRONT SUSPENSION>Front Arm>INSTALLATION

10.

Connect the tie-rod ends.

 

Do not apply grease, etc. to the tapered portion of ball stud.

(1)

Tighten the castle nut.

 

If the ball stud hole and the cutout portion of the castle nut are not aligned after tightening, tighten the castle nut within the range of 60° to align with each other.

Tightening torque:

27 N·m (2.8kgf-m, 19.9ft-lb)

(2)

Install a new cotter pin.

11.

Install the stabilizer. FRONT SUSPENSION>Stabilizer>INSTALLATION > STABILIZER

12.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

13.

Install the crossmember support front and the crossmember support rear. FRONT SUSPENSION>Crossmember Support>INSTALLATION

14.

Install the under cover front.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

15.

Install the front wheels and lower the vehicle.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

16.

Install the air cleaner case. INTAKE (INDUCTION)(H4DO)>Air Cleaner Case>INSTALLATION

17.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

18.

Install the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>ASSEMBLY

19.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

20.

Inspect the wheel alignment and adjust if necessary.

21.

Perform the following adjustments using Subaru Select Monitor.

FRONT SUSPENSION > Front Strut　
REMOVAL
1.

Lift up the vehicle, and then remove the front wheels.

2.

Disconnect the stabilizer link front (upper part) on the left and right sides.

3.

Remove the brake hose bracket.

4.

Remove the sensor sub assembly front.

5.

Remove the strut assembly.

(1)

Place an alignment mark (a) on the adjusting bolt and the strut assembly.

(2)

Remove the adjusting bolts and flange bolts for the strut assembly.

 

Turn and remove the nut while holding the bolt side.

(3)

Remove the three nuts securing the mount strut front to the body.

FRONT SUSPENSION > Front Strut　
INSTALLATION
 

For parts which are not reusable, always use new parts.

1.

Install the mount strut front at the upper side of the strut assembly to the vehicle body.

Tightening torque:

32 N·m (3.3kgf-m, 23.6ft-lb)

2.

Align alignment marks on the camber adjusting bolt and the strut assembly, and install the strut assembly to the front axle housing.

 

While holding the bolt side, tighten the nut to the specified torque.

 

First, tighten the adjusting bolt (upper side) to the specified torque.

Tightening torque:

155 N·m (15.8kgf-m, 114.3ft-lb)

3.

Install the sensor sub assembly front and harness bracket.

 

During the installation, make sure that the marking of sensor sub assembly front harness does not twist.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

4.

Install the brake hose bracket.

Tightening torque:

33 N·m (3.4kgf-m, 24.3ft-lb)

5.

Install the stabilizer link front.

Tightening torque:

60 N·m (6.1kgf-m, 44.3ft-lb)

6.

Lower the vehicle, and install the front wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

7.

Inspect the wheel alignment and adjust if necessary.

8.

Perform the following adjustments using Subaru Select Monitor.

FRONT SUSPENSION > Front Strut　
DISASSEMBLY
1.

Using a coil spring compressor, compress the coil spring.

Preparation tool:

Coil spring compressor

2.

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

 

When installing the coil spring compressor to the coil spring, follow the operation manual accompanied with the coil spring compressor during operation.

Preparation tool:

ST: STRUT MOUNT SOCKET (20399AG000)

 

<Example of coil spring compressor installation>

The installing position of coil spring compressor varies depending on the coil spring shape and winding number.

3.

Remove the mount strut front, the mount bearing front and the dust cover front from the strut COMPL front.

4.

Gradually decrease the compression force of compressor, and remove the coil spring.

5.

Remove the helper front.

FRONT SUSPENSION > Front Strut　
ASSEMBLY
1.

Before assembly, check each part. FRONT SUSPENSION>Front Strut>INSPECTION

2.

Using a coil spring compressor, compress the coil spring.

 

When installing the coil spring compressor to the coil spring, follow the operation manual accompanied with the coil spring compressor during operation.

 

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

(a)

Diameter is large (upper part)

(b)

Identification paint

(c)

Diameter is small (bottom part)

Preparation tool:

Coil spring compressor

3.

Install the rubber seat LWR to the strut COMPL front.

 

Make sure the coil seating section of the rubber seat is free from foreign matters such as pebbles. Remove the foreign matters such as pebbles if any.

4.

Set the coil spring correctly so that the spring end face (a) fits within the area (c) of the cutout portion (b) of rubber seat LWR as shown in the figure.

5.

Install the helper front to the piston rod.

6.

Pull the piston rod fully upward, and install the dust cover front.

7.

Install the mount strut front.

 

Make sure that the mount bearing front turns smoothly after tightening.

(1)

Temporarily assemble the mount strut front and the mount bearing front, and install it to the piston rod.

(2)

Temporarily tighten the mount strut front with a new self-locking nut.

(3)

Using a hexagon wrench, prevent the piston rod of strut COMPL front from turning.

(4)

Using the ST, tighten the self-locking nut to the specified torque.

Preparation tool:

ST: STRUT MOUNT SOCKET (20399AG000)

Tightening torque:

55 N·m (5.6kgf-m, 40.6ft-lb)

8.

Loosen the coil spring compressor carefully.

FRONT SUSPENSION > Front Strut　
INSPECTION

Check the removed part for wear, damage and cracks, and then repair or replace it if defective.

1. STRUT COMPL FRONT
1.

Check for oil leaks.

2.

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

3.

Check the piston rod runout.

Preparation tool:

Dial gauge

Magnet stand

(1)

Fix the outer shell.

(2)

Extend the piston rod until it stops retracting, and set the dial gauge at the L position from the end of the piston rod.

Measuring point:

L = 10 mm (0.39in)

(3)

While applying a force of W1 [20 N (2 kgf, 4 lbf)] to the arrowed section, read the dial gauge indication P1.

(4)

While applying a force of W2 [20 N (2 kgf, 4 lbf)] from the opposite side of W1, read the dial gauge indication P2.

Play limit (P1 + P2):

0.8 mm (0.031in)

4.

Replace the strut COMPL front if a fault is found in the inspection or limit value is exceeded.

2. MOUNT STRUT FRONT

Check the rubber part for deformation, cracks or deterioration, and then replace it with a new part if defective.

3. RUBBER SEAT LWR

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

4. MOUNT BEARING FRONT

If abnormal cracks or any abnormality in rotation are found, replace it with a new part.

5. COIL SPRING FRONT

If cracks, damage or deformation are found, replace it with a new part.

6. HELPER FRONT

If major cracks or damage are found, replace it with a new part.

7. DUST COVER FRONT

If major cracks or damage are found, replace it with a new part.

FRONT SUSPENSION > Front Strut　
DISPOSAL
 

  • Before handling the strut damper and shock absorber, be sure to wear goggles to protect eyes from gas, oil and cutting powder.

  • Do not disassemble the strut damper and shock absorber or place them into a fire.

  • When discarding gas filled strut dampers and shock absorbers, drill holes in them to purge the gas.

1.

Place the strut damper and shock absorber on a level surface with the piston rod fully expanded.

2.

Make a hole of 30 mm (1.18in) deep into the specified position shown in the figure, using a drill with 2 — 3 mm (0.08 — 0.12in) diameter.

(a)

40 mm (1.57in)
FRONT SUSPENSION > General Diagnostic Table　
INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER SUSPENSION HEIGHT

Possible cause

Corrective action

(1) Deformation or damage of suspension parts

Replace.

(2) Defective strut COMPL front

Replace.

(3) Improper installation of strut assembly

Replace with appropriate parts.

(4) Installation of the wrong coil spring

Replace with appropriate parts.
2. POOR RIDE COMFORT
1.

Large rebound shock.

2.

Rocking of the vehicle continues too long after running over bump and hump.

3.

Excessive shock in bumping.

Possible cause

Corrective action

(1) Damaged coil spring

Replace.

(2) Overinflation of tires

Adjust to the specified air pressure.

(3) Improper suspension height

Replace the coil springs with new parts.

(4) Fault in operation of strut COMPL front

Replace.

(5) Damage or deformation of mount strut front

Replace.

(6) Unsuitable length (maximum or minimum) of strut COMPL front

Replace with appropriate parts.

(7) Abnormal deformation or loss of bushing

Replace.

(8) Deformation or damage of helper in strut assembly

Replace.

(9) Oil leakage from the strut COMPL front

Replace.
3. NOISE

Possible cause

Corrective action

(1) Wear or damage of strut COMPL front component parts

Replace.

(2) Loosening of the suspension link installing bolt

Tighten to the specified torque.

(3) Abnormal deformation or loss of bushing

Replace.

(4) Unsuitable length (maximum or minimum) of strut COMPL front

Replace with appropriate parts.

(5) Damaged coil spring

Replace.

(6) Wear or damage of the ball joint

Replace.

(7) Deformation of the clamp stabilizer

Replace.