Subaru Legacy 2004 Service Manual CHASSIS SECTION

2004 LEGACY 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
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas­sembling, inspection and ad justment of
components and diagnostics for guid­ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

TRANSFER CASE TC

DRIVE SHAFT SYSTEM DS

ABS ABS

ABS (DIAGNOSTICS) ABS(diag)

VEHICLE DYNAMICS CONTROL (VDC) VDC

VEHICLE DYNAMICS CONTROL (VDC)
(DIAGNOSTICS)

VDC(diag)

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

FUJI HEAVY INDUSTRIES LTD. G2320GE6

BRAKE BR

PARKING BRAKE PB

POWER ASSISTED SYSTEM
(POWER STEERING)

PS

FRONT SUSPENSION

Page

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

2. Wheel Alignment.........................................................................................8

3. Front Crossmember Support Plate ................ .................... .................... ...15

4. Front Stab il i z e r............... ............. .. .............. .. ............. ............. ... ............. ..16

5. Front Ball J o in t .... .. ............. ... ............. .. ............. ... ............. .. ............. .. ....... 17

6. Front Arm ... .. .............. .. ............. .. ............. ... ............. ............. .. .............. .. ..19

7. Front Stru t .... .............. ............. .. ............. .. .............. .. ............. ............. ... ....22

8. Front Cros s m e mb e r .............. .. ............. ............. ... ............. .. ............. .........26

9. General Diagnostic Table..........................................................................27

FS

FRONT SUSPENSION

1. General Description

A: SPECIFICATION

Model

Wheel arch height

−0.94 in

−0.94 in

+12

+12

−24 mm

)]

−24 mm

)]

mm (in) 376 (14.8) 381 (15.0) 376 (14.8) 429 (16.9)

Inner
wheel

Outer
wheel

mm (in) 360 (14.2) 375 (14.8) 430 (16.9)

[Tolerance:

+0.47 in

(
Camber (Tolerance: ±0°45′

Differences between RH and
LH: 45′ or less)

Caster 6°00′ 5°45′ 5°05′

Front

Steering angle (Toler­ance: ±1.5°)

Toe-in mm (in) 0±3 (0±0.12) Toe angle (sum of both wheels): 0°±0°15′
Kingpin angle 13°50′ 13°45′ 13°50′ 12°25′
Diameter of stabilizer mm (in) 20 (0.79) 21 (0.83) 20 (0.79) 21 (0.83)
Wheel arch height

[Tolerance:

+0.47 in

(
Camber (Tolerance: ±0°45′

Differences between RH and

Rear

LH: 45′ or less)
Toe-in mm (in) 0±3 (0±0.12) Toe angle (sum of both wheels): 0°±0°15′
Thrust angle (Tolerance: ±0°30′)0°

Diameter of stabilizer mm (in) 17.3 (0.68) 19.1 (0.75)

General Description

Sedan Wagon

2.0 i 2.5 i 2.0 GT 3.0 R 2.0 i 2.5 i 2.0 GT 3.0 R

−0°20′−0°15′−0°20′ 0°30′

37.3° 37.8°

33.0° 33.5°

−0°45′−0°30′ 0°00′

20

(0.78)

19.1 (0.75) 17.3 (0.68)

OUTBACK

2.5 i,

OUTBACK

3.0 R

FS-2

General Description

NOTE:

1

• Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tol erance exceeds
specifications, adjust them.

• Other items indicated in the specification table
cannot be adjusted. If those items exceed specifi­cations, check suspension parts and connections
for deformities; replace with new ones as required.

B

(1)

FRONT SUSPENSION

A

(1) Front

A − B = Positive: Toe-in, Negative: Toe-out
α = Each toe angle

FS-0000

FS-3

FRONT SUSPENSION

B: COMPONENT

T1

General Description

(25)

(22)

(20)

(16)

(17)

(18)

(19)

T6

(21)

(23)

(15)

T7

T7

(12)

(25)

(13)

(1)

(25)

(7)

T4

T7

T5

T8

T8

T4

(25)

T9

(8)

(6)

(3)

(4)

(24)

T3

(26)

(2)

(5)

T9

(25)

T10

(11)

(10)

T2

T7

(25)

T11

(1) Front crossmember (14) Crossmember support plate
(2) Housing T1: 20 (2.0, 14.5)

(Small type)

(9)

(14)

T7

(25)

T2

Tightening torque: N⋅m (kgf-m, ft-lb)

(3) Ball joint (15) Jack-up plate T2: 25 (2.5, 18.1)
(4) Front arm (16) Dust seal T3: 39 (4.0, 28.8)
(5) Support plate (17) Strut mount T4: 45 (4.6, 33.2)
(6) Rear bushing (18) Upper spring seat T5: 50 (5.1, 36.9)
(7) Front bushing (19) Dust cover T6: 55 (5.6, 41)
(8) Stud bolt (20) Helper T7: 60 (6.1, 44.3)

(9) Stabilizer link (21) Coil spring T8: 95 (9.7, 70.1)
(10) Bracket (22) Damper strut T9: 110 (11.2, 81.1)
(11) Bushing (23) Adjusting bolt T10: 150 (15.3, 110.6)
(12) Stabilizer (24) Castle nut T11: 175 (17.8, 129)
(13) Crossmember support plate

(Large type)

(25) Self-locking nut
(26) Cotter pin

FS-00131

FS-4

General Description

C: CAUTION

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

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

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

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

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

• Place shop jacks or rigid racks at the specified
points.

FRONT SUSPENSION

FS-5

FRONT SUSPENSION

2

0

D: PREPARATION TOOL

1. SPECIAL TOOL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

927380002 ADAPTER Used as an adapter for camber & caster gauge

(1)

(2)

ST-92738000

927680000 INSTALLER &

General Description

when measuring cambe r and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT

Used for replacing the front arm front bushing.

REMOVER SET

ST-92768000

ST20299AG000

20299AG000

(Newly adopted tool)

20299AG010

(Newly adopted tool)

REMOVER Used for replacing the front arm rear bushing.

Used with BASE (20999AG010).

BASE Used for replacing the front arm rear bushing.

Used with REMOVER (20999AG000).

ST20299AG010

FS-6

General Description

FRONT SUSPENSION

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

20299AG020

(Newly adopted tool)

ST20299AG020

20399AG000

(Newly adopted tool)

STUD BOLT
SOCKET

STRUT MOUNT
SOCKET

Used for remo ving an d instal ling t he stud bol t f or
front arm installing portion.

Used for dis assemb ling an d assem blin g the strut
mount.

ST20399AG000

2. GENERAL TOOL

TOOL NAME REMARKS
Alignment gauge Used for wheel alignment me asurement.
Turning radius gauge Used for wheel alignment measurement.
Toe-in gauge Used for toe-in measurement.
Dial gauge Used for damper strut measurement.
Coil spring compressor Used for strut assembly/disassembly.

FS-7

Wheel Alignment

FRONT SUSPENSION

2. Wheel Alignment

A: INSPECTION

Check the following items before taking wheel alignment measurement.
Check items before taking wheel alignment measurement:

• Tire inflation pressure

• Unbalanced right and left tire wear, size difference

• Tire runout

• Excessive play and wear in ball joint

• Excessive play and wear in tie rod end

• Excessive play in wheel bearing

• Right and left wheel base imbalance

• Deformation and excessive play in steering li nk

• Deformation and excessive play in suspension parts
Check, adjust and measure the wheel alignment in accordance with the procedures indicated in the figure.

Wheel arch height (front and rear wheels)

<Ref. to FS-9, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>

↓

Camber (front and rear wheels)

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

↓

Caster (front wheel)

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

↓

Steering angle

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

↓

Front wheel toe-in

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

↓

Rear wheel toe-in

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

↓

Thrust angle

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

FS-8

Wheel Alignment

FRONT SUSPENSION

1. WHEEL ARCH HEIGHT

1) Park the vehicle on a level surface.

2) Set the vehicle under “curb weight” condition.
(Make the luggage compartment empty, install the
spare tire, jack and service tools, and top up the
fuel tank.)

(2)

A

(1)

3) Set the steering wheel in a straight-ahead posi­tion, and stabilize the suspensions by moving the
vehicle straight more than 5 m (16 ft).

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

5) Measure the distance between the poi nt “ A” and
the center of wheel.

(3)

A

(1)

A

(6)

(7)

(4)

(1) Wheel arch height (4) Front wheel arch height (7) Point of measurement
(2) Front fender (5) Rear whee l arch hei ght (8) Tip end of spindle
(3) Rear quarter (6) Flange bend line

Wheel arch height standard value mm (in) (Tolerance ±12 mm)

Sedan Wagon

Model

Front 376 (14.8) 381 (15.0) 376 (14.8) 429 (16.9)
Rear 360 (14.2) 375 (14.8) 430 (16.9)

2.0 i 2.5 i 2.0 GT 3.0 R 2.0 i, 2.5 i 2.0 GT, 3.0 R

(5)

(1)

(8)

FS-00125

OUTBACK

2.5 i,

OUTBACK

3.0 R

FS-9

FRONT SUSPENSION

NOTE:

NOTE:

7

Wheel Alignment

2. CAMBER

• INSPECTION

1) Place the front wheel on turning radius gauge.
Make sure the 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 set
the wheel alignment gauge.
ST 927380002 ADAPTER

ST

(1)

(2)

(1) Alignment gauge
(2) Turning radius gauge

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

FS-0000

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

Moving the adjusting bolt by one s cale changes th e
camber by approx. 0°15′.

(1)

(4)

(6) (7)

(5)

(2)

Camber (Diff erences betwee n

RH and LH: 45′ or less)

0°30′±0°45′

Wagon

Model

Sedan −0°20′±0°45′

2.0 i, 2.5 i −0°15′±0°45′

2.0 GT, 3.0 R −0°20′±0°45′
OUTBACK 2.5 i,

OUTBACK 3.0 R

• FRONT CAMBER ADJUSTMENT

1) When adjusting the camber, adjust it to the fol­lowing value.

Camber (Diff erences betwee n

RH and LH: 45′ or less)

0°30′±0°30′

Wagon

Model

Sedan −0°20′±0°30′

2.0 i, 2.5 i −0°15′±0°30′

2.0 GT, 3.0 R −0°20′±0°30′
OUTBACK 2.5 i,

OUTBACK 3.0 R

2) Loosen the two self-locking nuts located at the
lower front po rt io n of strut.

When the adjusting bolt needs to be loosened or
tightened, hold its head with a wrench an d tur n the
self-locking nut.

(3)

FS-00008

(1) Strut
(2) Adjusting bolt
(3) Housing
(4) Outer
(5) Inner
(6) Camber is increased.
(7) Camber is decreased.

FS-10

Wheel Alignment

9

0

0

9

7

FRONT SUSPENSION

To increase camber.

Rotate the left side counterclockwise. Rotate the right side clockwise.

FS-0000

To decrease camber.

Rotate the left side clockwise. Rotate the right side counterclockwise.

FS-0001

4) Tighten two new self-locking nuts.

Tightening torque:

175 N

⋅

m (17.8 kgf-m, 129 ft-lb)

3. CASTER

• INSPECTION

1) Place the front wheel on turning radius gauge.
Make sure the 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 set
the wheel alignment gauge.
ST 927380002 ADAPTER

ST

FS-0001

FS-0000

3) Measure the caster angle in accor dance with the
operation manual for wheel alignment gauge.

Model Caster
Sedan 6°00′
Wagon 5°45′
OUTBACK 5°05′

4. STEERING ANGLE

• INSPECTION

1) Place the vehicle on turning radius gauge.

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

(1)

(2)

(1) Alignment gauge
(2) Turning radius gauge

Model Inner wheel Outer wheel

FS-0000

OUTBACK 37.8°±1.5
Except for OUT-

BACK

37.3°±1.5

°

°

33.5°±1.5

33.0°±1.5

°

°

FS-11

FRONT SUSPENSION

NOTE:

NOTE:

NOTE:

4

5

4

Wheel Alignment

• ADJUSTMENT

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

2) Check the toe-in.

Correct the boot if it is twisted.

(1)

FS-0001

(1) Lock nuts

5. FRONT WHEEL TOE-IN

• INSPECTION

Toe-in:

±

3 mm (0±0.12 in)

0

1) Set the toe-in gauge in the p osition at wheel axis
center height behind the right and left front tires.

2) Measure the distance “A” between the marks
which are put on the centers of left and right tires.

3) Move the vehicle forward and 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. Detect toe-in by the f ollowing equation:

−

B = Toe-in

A

• ADJUSTMENT

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

Toe-in:

0

±

2 mm (0±0.08 in)

1) Check that the left and right wheel steeri ng angle
is within specifications.

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

3) Turn the left and right t ie rods 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 t he inside
of vehicle).

(1)

FS-0001

(1) Lock nuts

4) Tighten the tie-rod lock nut.

Tightening torque:

⋅

m (8.7 kgf-m, 62.7 ft-lb)

85 N

Check and correct the tie rod boot if twisted.

6. REAR WHEEL TOE-IN

• INSPECTION

Toe-in:

±

3 mm (0±0.12 in)

B

A

0

Refer to “FRONT WHEEL TOE-IN” for rear toe-in
inspection procedure.
<Ref. to FS-12, FRONT WHEEL TOE-IN, INSPEC­TION, Wheel Alignment.>

• ADJUSTMENT

When adjusting, adjust it to the following value.

FS-0001

Toe-in:

±

2 mm (0±0.08 in)

0

FS-12

Wheel Alignment

NOTE:

NOTE:

8

9

9

8

FRONT SUSPENSION

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

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

(1)

(2)

FS-00103

(1) Adjusting bolt
(2) Rear link

To increase toe-in.

Rotate the left side clockwise. Rotate the right side counterclockwise.

2) Turn the adjusting bolt unti l toe-in i s at the spec­ification.

When the left and right wheels ar e adjusted for toe­in at the same time, the movement of one scale
graduation changes toe-in by approx. 0.6 mm (0.02
in).

Rotate the left side counterclockwise. Rotate the right side clockwise.

3) Tighten a new self-locking nut.

Tightening torque:

⋅

120 N

m (12.2 kgf-m, 88.5 ft-lb)

FS-0001

To decrease toe-in.

FS-0001

FS-0001

FS-0001

FS-13

FRONT SUSPENSION

NOTE:

4

Wheel Alignment

7. THRUST ANGLE

• INSPECTION

1) Park the vehicle on a level surface.

2) Move the vehicle 3 to 4 meters (10 to 13 feet) di­rectly forwar d .

3) Draw the center of loci of both the front and rear
axles.

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

Thrust angle:

°±30′

0
Less than 30′ when “L” is less than 23 mm
(0.9 in).

(1)

(2)

3) When the left and right adjus ting bolts are turne d
by one graduation, the thrust angle will change ap­prox. 17′ [“L” is approx. 13 mm (0.51 in)].

Thrust angle refers to a mean value of left and right
rear 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.

(1)

(3)

(2)

FS-0002

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

L

FS-00022

(1) Center line of loci (front axle)
(2) Center line of loci (rear axle)

• ADJUSTMENT

When adjusting, adjust it to the following value.

Thrust angle:

°±20′

0
Less than 20′ when “L” is less than 15 mm
(0.6 in).

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

2) When one rear wheel is adjusted in a toe-in di­rection, adjust the other rear wheel equally in toe­out direction, in order to make the thrust angle ad­justment.

α − β

Thrust angle: r = (

)/2

α: Rear RH wheel toe-in angle
β: Rear LH wheel toe-in angle

Use only positive toe-in values from each wheel to
substitute for α and β in the equation.

(1)

(1) Front
(2) Body center line

(2)

FS-00976

FS-14

Front Crossmember Support Plate

NOTE:

3. Front Crossmember Support Plate

A: REMOVAL

1) Lift-up the vehicle.

2) Remove the front under cover. <Ref. to EI-26,

REMOVAL, Front Under Cover.>

3) Remove the bolt and remove front cro ssmember

support plate.

• Large type

FS-00104

•Small type

FRONT SUSPENSION

(1)

(1) Crossmember support plate
(2) Jack-up plate

(2)

(1)

FS-00105

B: INSTALLATION

Install in the reverse order of removal.

Tighten the small type crossmember support plate
together with stabilizer bracket.
After installing the stabilizer bracket to crossmem­ber, tighten the crossmember support plate toget h­er.

Tightening torque:

Crossmember support plate:

⋅

m (6.1 kgf-m, 44.3 ft-lb)

60 N
Crossmember support plate (Joint tightening
portion of stabilizer bracket):

⋅

m (2.5 kgf-m, 18.1 ft-lb)

25 N
Jack-up plate:

60 N

⋅

m (6.1 kgf-m, 44.3 ft-lb)

FS-15

FRONT SUSPENSION

NOTE:

Front Stabilizer

4. Front Stabilizer

A: REMOVAL

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

2) Remove the front under cover. <Ref. to EI-26,
REMOVAL, Front Under Cover.>

3) Remove the front crossmember support plate.
<Ref. to FS-15, REMOVAL, Front Crossmember
Support Plate.>

4) Remove the stabilizer link.

FS-00117

5) Remove the stabilizer bracket.

• Stabilizer bracket has an orientation, so install it
with the arrow mark faced to the front side of vehi­cle.

(1)

FS-00116

(1) Front side of vehicle

Tightening torque:

Stabilize r li n k

⋅

m (4.6 kgf-m, 33.2 ft-lb)

45 N

Stabilizer bracket

⋅

m (2.5 kgf-m, 18.1 ft-lb)

25 N

C: INSPECTION

1) Check the bushing for crack , fat igue or damage.

2) Check the stabilizer link for damage.

FS-00114

B: INSTALLATION

Install in the reverse order of removal.

• Use a new self-locking nut.

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

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

FS-16

Front Ball Joint

CAUTION:

NOTE:

5

6

5. Front Ball Joint

A: REMOVAL

1) Lift-up the vehicle and remove the front wheels.

2) Remove the both sides of stabilizer bracket.

FRONT SUSPENSION

Stabilizer bracket has an orientation, so install it
with the arrow mark faced to the front side of vehi­cle.

(1)

FS-00114

3) Pull out the pin from ball stud, remove the castle
nut, and extract the ball stud from front arm.

4) Remove the bolt installing ball joint to housing.

FS-00115

5) Extract the ball joint from housing.

B: INSTALLATION

1) Insert the ball joint into housing.

Tightening torque (Bolt):

⋅

m (5.1 kgf-m, 36.9 ft-lb)

50 N

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

2) Install the ball joint into front arm.

Tightening torque (Castle nut)

Front arm:

⋅

m (4.0 kgf-m, 28.8 ft-lb)

39 N

3) Retighten the castle nut further within 60° until
the hole in ball stud is aligned with a slot in castle
nut. Then, insert a new cotter pin and bend it
around castle nut.

4) Install the stabilizer bracket.

FS-00116

(1) Front side of vehicle

Tightening torque:

⋅

m (2.5 kgf-m, 18.1 ft-lb)

25 N

5) Install the front wheels.

C: INSPECTION

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

(1) With 686 N (70 kgf, 154 lb) loaded in direc­tion shown in the figure, measur e the dimen sion

.

2

1

FS-0003

(2) With 686 N (70 kgf, 154 lb) loaded in direc­tion shown in the figure, measur e the dimen sion

2

.

2

FS-0003

(3) Determine the plays from the following for­mula. S = 2

– 2

2

1

FS-17

Front Ball Joint

FRONT SUSPENSION

(4) Replace with a new one when the play ex­ceeds specified value.

FRONT BALL JOINT

Specified play for replacement S:

Less than 0.3 mm (0.012 in)

2) When the play is within specified value, visually
check the dust cover.

3) Remove the ball joint and cover, check them for
wear, damage or cracks, and then replace them if
any defective part is found.

4) If the dust cover is damaged, replac e with a new
ball joint.

FS-18

Front Arm

CAUTION:

NOTE:

6. Front Arm

A: REMOVAL

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

2) Remove the front crossmember support plate.
<Ref. to FS-15, REMOVAL, Front Crossmember
Support Plate.>

3) Remove the front stabilizer. <Ref . t o FS-16, RE­MOVAL, Front Stabilizer.>

4) Remove the ball joint of front arm.

FS-00106

5) Remove the nut securing the front arm to cross­member. (Do not remove the bolt.)

FRONT SUSPENSION

Do not remove the stud bolt without necessity.
Always replace the parts with new ones when
removed.

(1)

(2)

ST

FS-00109

(1) Vehicle body
(2) Stud bolt

B: INSTALLATION

1) Using the ST, install the stud bolt.
ST 20299AG020 STUD BOLT SOCKET

Tightening torque:

⋅

110 N

2) Using new bolts and s elf-locking nuts, temporari­ly tighten the front arm to crossmember.

3) Secure the front arm to bo dy, and then ins tall the
support plate with new bolts and self-locking nuts.

m (11.2 kgf-m, 81.1 ft-lb)

FS-00107

6) Remove the front arm support plate.

FS-00108

7) Remove the bolt securing the front arm to cros s­member and extract the front arm from crossmem­ber.

8) To remove the stud bolt, use ST.
ST 20299AG020 STUD BOLT SOCKET

Tightening torque:

Support plate-to-Front arm:

⋅

110 N

m (11.2 kgf-m, 81.1 ft-lb)

Support plate-to-Body:

150 N

⋅

m (15.3 kgf-m, 110.6 ft-lb)

4) Install the ball joint into housing.

Tightening torque:

⋅

m (5.1 kgf-m, 36.9 ft-lb)

50 N

5) Install the stabiliz er. <Ref. to FS-16, INSTALLA­TION, Front Stabilizer.>

6) Lower the vehicle from the lift, and tighten the
bolt which secures the front arm to crossmember at
the state that wheels are in full contact with the
ground and the vehicle is curb weight.

Tightening torque:

⋅

m (9.7 kgf-m, 70.1 ft-lb)

95 N

Inspect the wheel alignment and adjust if neces­sary.

FS-19

FRONT SUSPENSION

CAUTION:

CAUTION:

6

Front Arm

C: DISASSEMBLY

1. FRONT BUSHING

Using the ST and a press, remove the front bush­ing.
ST 927680000 INSTALLER & REMOVER

SET

ST

FS-00110

2. REAR BUSHING

1) Scribe an aligning mark on the front arm based
on the center of rear bushing recess portion.

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

2) Using the ST and a press, remove the rear bush­ing.
ST1 20299AG000 REMOVER
ST2 20299AG010 BASE

(1)

(2)

(3)

(1) Press
(2) Front arm
(3) Rear bushing

ST1

ST2

FS-00126

D: ASSEMBLY

1. FRONT BUSHING

Assemble in the reverse order of disassembly.

Install the front bushing in proper direction as
shown in the figure.

(1)

(1) Put an alignment mark.
(2) Recess portion

(1)

(2)

FS-0013

(3)

(1)

(2)

FS-00102

(1) Face the bushing toward the center of ball joint.
(2) Ball joint
(3) ±3°

FS-20

Front Arm

6

FRONT SUSPENSION

2. REAR BUSHING

1) Install the rear bushing with its longer inner cyl­inder faced upward and its shorter on e faced down­ward and protruding part rearward as shown in the
figure.

(1)

(5)

(3)

(4)

(2)

FS-00113

(1) Front arm
(2) Bushing inner cylinder
(3) Longer
(4) Shorter
(5) Protrusion portion

2) Align the center of rear bushing recess portion
with the aligning mark on the front arm.

3) Using the ST and a press, install the rear bush­ing.
ST1 20299AG000 REMOVER
ST2 20299AG010 BASE

(1)

ST1

(2)

(1) Press
(2) Front arm
(3) Rear bushing

(3)

ST2

FS-00127

E: INSPECTION

1) Check the front arm for wear, damage or crac ks,
and correct or replace if defective.

2) Check the bushing for crack , fat igue or damage.

(1) Alignment mark
(2) Recess portion

(1)

(2)

(1)

FS-0013

FS-21

FRONT SUSPENSION

NOTE:

NOTE:

NOTE:

7

8

Front Strut

7. Front Strut

A: REMOVAL

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

2) Scribe an alignment mark on th e camber adj ust­ing bolt and strut.

3) Remove the bolt securing brake hose fr om strut.

FS-0003

4) Remove the bolt securing ABS wheel speed
sensor harness.

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

FS-00039

FS-0003

5) Remove the two bolts securing housing to strut.

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

B: INSTALLATION

1) Install the strut mount at t he upper side of strut to
body, and tighten it with new self-lock ing nuts.

Tightening torque:

⋅

m (2.0 kgf-m, 14.5 ft-lb)

20 N

2) Align alignment marks on the camber adjusting
bolt and strut.
Using new self-locking nuts, install the strut to
housing.

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

Tightening torque:

⋅

175 N

3) Secure the ABS wheel speed sensor harness to
strut.

Tightening torque:

33 N

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

Tightening torque:

33 N

5) Install the front wheels.

m (17.8 kgf-m, 129 ft-lb)

⋅

m (3.4 kgf-m, 24.3 ft-lb)

⋅

m (3.4 kgf-m, 24.3 ft-lb)

Inspect the wheel alignment and adjust if neces­sary.

FS-22

Front Strut

NOTE:

NOTE:

0

1

2

3

FRONT SUSPENSION

C: DISASSEMBLY

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

FS-0004

2) Using the ST, remove the self-locking nut.
ST 20399AG000 STRUT MOUNT SOCKET

ST

FS-0004

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

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

5) Remove the dust cover and helper spring.

(5) Repeat 3 to 4 times from the step (1).

After completely purging air from the strut, be sure
to place the strut wi th the piston r od facing up. If th e
strut is laid down and set, check for the entry of air
in accordance with “Check for presence of air”.

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

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

(1)

(2)

(3)

(1) Diameter is small (Upper part)
(2) Identificati on paint
(3) Diameter is large (Bottom part)

FS-0004

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

D: ASSEMBLY

1) Before installing the coil spring, st rut mount , etc.
on strut, check for the presence of air in t he damp­ening force generating mechanism of the strut
since air prevents proper dampening for ce produ c­tion.

2) Check for 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 ro d 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 the piston rod
facing up.
(2) Fully extend the piston rod.
(3) With the piston rod ful ly ext ended, place the
piston rod side down. The strut must stand ver­tically.
(4) Fully contract the piston rod.

(1)

FS-0004

(1) Coil spring end face

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

FS-23

FRONT SUSPENSION

NOTE:

8

1

6

Front Strut

7) Pull the piston rod fully upward, and install the

spring seat.

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

(1)

(1) Outside of body

FS-0012

8) Install the strut mount to pist on rod, and tighten a

new self-locking nut temporarily.

9) Using a hexagon wrench to prevent strut rod

from turning, tighten the new self-locking nut with
ST.
ST 20399AG000 STRUT MOUNT SOCKET

E: INSPECTION

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

1. DAMPER STRUT

1) Check for oil leaks.

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

3) Piston rod play

• Measure the play as follows:
Fix the outer shell and fully extend the rod. Set a
dial gauge at the end of r od L [10 mm (0.39 in)], and
then read the dial gauge indication P
ing a force of W [20 N (2 kgf, 4 lb)] to threaded por­tion. Apply a force of 20 N (2 kgf, 4 lb) in the
opposite direction of “W”, and then read the dial
gauge indication P

W

.

2

L

while apply-

1

Tightening torque:

⋅

m (5.6 kgf-m, 41 ft-lb)

55 N

ST

10) Loosen the coil spring carefully.

FS-0004

FS-0004

Play limit (P

+ P2):

1

0.8 mm (0.031 in)

If the play exceeds limit, replace the strut.

2. STRUT MOUNT

Check the rubber part for deformation, cracks or
deterioration, and then 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

If a permanent strain is found, replaced it with a
new one.

5. HELPER

Replace it with a new one if cracked or damaged.

FS-24

Front Strut

CAUTION:

7

F: DISPOSAL

• Before handling struts, be sure to wear gog-

gles to protect eyes from gas, oil and cutting
powder.

• Do not disassemble the strut damper or place

into a fire.

• Drill a hole into struts in case of discarding

struts filled with gas.

1) Place the strut on a level surf ace with the piston

rod fully expanded.

2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,

make holes in areas shown in the figure.

FRONT SUSPENSION

(1) 40 mm (1.57 in)

(1)

FS-0004

FS-25

FRONT SUSPENSION

CAUTION:

NOTE:

Front Crossmember

8. Front Crossmember

A: REMOVAL

1) Lift-up the vehicle, and then remove the front

wheels.

2) Remove the front exhaust pipe.

3) Remove the front crossmember support plate.

<Ref. to FS-15, REMOVAL, Front Crossmember
Support Plate.>

4) Remove the front stabilizer. <Ref . t o FS-16, RE-

MOVAL, Front Stabilizer.>

5) Disconnect the tie-rod end from housing.

6) Remove the front arm. <Ref. to FS-19, REMOV-

AL, Front Arm.>

7) Remove the nuts attaching the engine mount

cushion rubber to crossmember.

FS-00118

8) Remove the steering universal joint.

9) Disconnect the power steering hose from steer-

ing gearbox.

10) Lift the engine approx. 10 mm (0.39 in) using a

chain block.

11) Support the crossmember with a jack, remove

the bolts securing crossmember to body, and then
gradually lower the crossmember with steering
gearbox as a unit.

When removing the crossmember downward,
be careful that the tie-rod end doe s not interfere
with drive shaft boot.

B: INSTALLATION

1) Install in the reverse order of removal.

• Use a new bolt and self-locking nut. For the parts
which are not reusable, refer to “COMPONENT”.
<Ref. to FS-4, COMPONENT, General Descrip­tion.>

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

Tightening torque:

Crossmember to body:

95 N

⋅

m (9.7 kgf-m, 70.1 ft-lb)

Engine mounting to crossmember:

⋅

m (8.7 kgf-m, 62.7 ft-lb)

85 N

Front arm-to-Crossmember:

⋅

m (9.7 kgf-m, 70.1 ft-lb)

95 N

Front arm-to-Support plate:

110 N

⋅

m (11.2 kgf-m, 81.1 ft-lb)

Support plate body:

⋅

150 N

Tie-rod end to housing:

27.0 N

Retighten the castle nut further within 60° until the
hole in ball stud is aligned with a slot in castle nut
after tightening in specified torque.

Universal joint:

24 N

Stabilizer bracket:

25 N

Stabilize r li n k:

45 N

Power steering hose-to-Steering gearbox:

15 N

2) Purge air from the power steering system.

3) Inspect the wheel alignment and adjus t if neces­sary.

m (15.3 kgf-m, 110.6 ft-lb)

⋅

m (2.75 kgf-m, 19.9 ft-lb)

⋅

m (2.4 kgf-m, 17.4 ft-lb)

⋅

m (4.6 kgf-m, 33.2 ft-lb)

⋅

m (2.5 kgf-m, 18.4 ft-lb)

⋅

m (1.5 kgf-m, 11 ft-lb)

C: INSPECTION

Check the crossmember for wear, damage or
cracks, and then repair or replace if defec tive.

FS-00119

FS-26

General Diagnostic Table

FRONT SUSPENSION

9. General Diagnostic Table

A: INSPECTION

1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT

Possi ble cause Corrective action
(1) Permanent distortion or breakage of coil spring Replace.
(2) Rough operation of damper strut or shock absorber Replace.
(3) Installation of wrong strut 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 afte r running over bump and hump.

3) Large shock in bumping

Possi ble cause Corrective acti on
(1) Breakage of coil spring Replace.
(2) Overinflating pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace the coil springs with new ones.
(4) Fault in operation of damper strut or shock absorber Replace.
(5) Damage or deformation of strut mount or shock absorber mount Replace.
(6) Unsuitability of maximum or minimum length of damper strut or shock

absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly or shock absorber Replace.
(9) Oil leakage of damper strut or shock absorber Replace.

Replace with proper parts.

3. NOISE

Possi ble cause Corrective action
(1) Wear or damage of damper strut or shock absorber component parts Replace.
(2) Loosening of suspension link installing bolt Tighten to specified torque.
(3) Deformation or loss of bushing Replace.
(4) Unsuitability of maximum or minimum length of damper strut or shock

absorber
(5) Breakage of coil spring Replace.
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.

Replace with proper parts.

FS-27

FRONT SUSPENSION

General Diagnostic Table

FS-28