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I a
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
~~

CHASSIS SECTION

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
c- .
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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.

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. G18306E5
FRONT SUSPENSION

FSr
1. General Description .................................................................................... 2
2. Wheel Alignment ......................................................................................... 8
3. Sub Frame ................................................................................................ 16
4. Front Transverse Link ............................................................................... 17
5. Front Ball Joint .......................................................................................... 19
6. Front Strut ................................................................................................. 20
7. Front Stabilizer .......................................................................................... 24
8. Front Crossmember .................................................................................. 25
9. General Diagnostic Table.......................................................................... 26
c- .
I GENERAL DESCRIPTION
FRONT SUSPENSION

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

2. WHEEL ALIGNMENT

Sedan Wagon
Model

Caster (common difference: f0'45') 3'35' I
I
3'25' I
I
3'35' I 3'25'
I
II 3'25'
. ~-

0+3 mm (Of0.12 in)
Toe-in
Each toe anale: kO"O7'30 (Total toe anale: fO"15')
I Kingpin angle (tolerance: +0"45') I 14"35' I 14"20' I 13"45' I 13"30' I 13'20'
Wheel arch height 396 mm 406 mm 387 mm 397 mm 402 mm
[tolerance: f 1 2 mm (f0.47 in)] (15.59 in) (15.98 in) (15.24 in) (15.63 in) (15.83 in)
AOTE:
Front and rear toe-ins and front camber can be
adjusted. If the 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
a = Each toe angle

FS-2
I GENERAL DESCRIPTION
FRONT SUSPENSION

c- .

FS-3
GENERAL DESCRIPTION
FRONT SUSPENSION

B: COMPONENT

FS-4
GENERAL DESCRIPTION
FRONT SUSPENSION

Front crossmember (17 )Dust seal Tightening torque: N.m (kgf-m, ft-lb)
Bolt ASSY (18) Strut mount T I : ZO(2.0, 14.5)
Housing (19) Spacer T2: 25 (2.5, 18.1) 1

Washer (20) Upper spring seat T3: 30 (3.1,22)
Stopper rubber (Rear) (21) Rubber seat T4: 34 (3.5,25)
Rear bushing (22) Dust cover T5: 40 (4.1, 30)
Stopper rubber (Front) (23) Helper T6: 45 (4.6, 33)
Ball joint (24) Coil spring T7: 50 (5.1, 37)
Transverse link (25) Damper strut T8: 55 (5.6, 41)
Cotter pin (26) Adjusting bolt T9: 71 (7.2, 52)
Front bushing (27) Castle nut T10: 100 (10.2, 74)
Stabilizer link (Except sedan turbo (28) Self-locking nut T11:
Clamp (30) Cover T12: 175 (17.8, 129)
Bushing (311 Clip T13: 190(19.4, 140)
Stabilizer (32) Stabilizer link (Sedan turbo model) T14: 250 (25.5, 184)
Jack-up plate

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.
c-- 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 REMARKS
927380002 sed as an adapter for camber & caster gauge
,hen measuring camber and caster.
I ) 28199AC000 PLATE
2) 28199AC010 BOLT

927680000 NSTALLER & Jsed for replacing transverse link bushing.
3EMOVER SET

84M2385
927760000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET and shock mount.

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
I
WHEEL ALIGNMENT
FRONT SUSPENSION

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

WHEEL ARCH HEIGHT (FRONT AND REAR)

1
CAMBER (FRONT AND REAR)

FRONT TOE-IN

REAR TOE-IN

THRUST ANGLE (REAR)

WHEEL STEERING ANGLE

B4M1OBBA

FS-8
I WHEEL ALIGNMENT I
FRONT SUSPENSION

1. WHEEL ARCH HEIGHT
1) Adjust the tire pressure to specifications.
2) Set the vehicle under "curb weight" conditions. (Empty luggage compartment, install spare tire, jack, ser-
vice tools, and top up fuel tank.)
3) Set the steering wheel in a wheel-forward position.
4) Suspend a thread from wheel arch (point " A in figure below) to determine the point directly above center
of spindle.
5 ) Measure the distance between measuring point " A and center of spindle.

E t
m
.- m
.-
a,
a, a,
.
c
.
c c
c E
2 m
.-
2 ca,
- m
a, a, .c
a, 2
m
c c
3
c
5
L
-
a,
a,
C m
e
LL
a,
a f
7 End of spindle;,y//,/

suo009

~
Model

Front
I Turbo
396k12 mm ( 5.59k0.47
1
~~

in)
Specified wheel arch height
Non-turbo
406kl2 mm ( 5.98k0.47
1 in)
Sedan
Rear 376k12 mm ( 4.80k0.47
1 in) 381532 mm (15.0k0.47 in)
Front 387k12 mm (15.24k0.47in) 397k12 mm (1 5.63k0.47in)
Wagon
Rear 376+12 mm ( 4.80k0.47
1 in) 381332 mm (15.0k0.47in)
Front - 402k12 mm ( 5.83k0.47
1 in)
OUTBACK
I Rear - 386k12 mm (15.20k0.47
in)

FS-9
I WHEEL ALIGNMENT
FRONT SUSPENSION

2. CAMBER 2) Turn the camber adjusting bolt so that the cam-
ber is set at the specification.
Inspection
NOTE:
1) Place the front wheel on turning radius gauge. Moving the adjusting bolt by one scale graduation
Make sure the ground contacting surfaces of front changes the camber by approximately 0'10'.
and rear wheels are set at the same height.
2) Set the ST into the center of the wheel, and then
install the wheel alignment gauge.
ST 927380002 ADAPTER

c- ~ (1) Alignment gauge
(2) Turning radius gauge

NOTE:
Refer to the `SPECIFICATIONS" for the camber
va Iues.
Front:
Rear: (2) Adjusting bolt
Front camber adjustment (3) Housing
(4) Outer
1) Loosen the two self-locking nuts located at the
(5) Inner
lower front portion of strut.
(6) Camber is increased.
CAUTION: (7) Camber is decreased.
When the adjusting bolt needs to be loos-
ened or tightened, hold its head with a wrench
and turn the self-locking nut.
Discard the loosened self-locking nut and re-
place with a new one.

FS-10
I WHEEL ALIGNMENT I
FRONT SUSPENSION

Left side Right side

Camber is increased.
J @) I
;hte counterclock-
@ Rotate clockwise.

u 04M0190 B4M03Gn

Camber is decreased. @ Rotate clockwise.
`
@
I
;?:e counterclock-
W
B4M0350 B4M0190

3 ) Tighten the two self-locking nuts. 4. FRONT WHEEL TOE-IN
--Tightening torque: Inspection
175 N.m (1 7.8 kgf-m, 129 ft-lb) 1) Using a toe gauge, measure the front wheel toe-
3. CASTER in.
Inspection Toe-in:
Of3 mm (OdU. 12 in)
1) Place the front wheel on turning radius gauge.
Make sure the ground contacting surfaces of front 2) Mark the rear sides of left and right tires at height
and rear wheels are set at the same height. corresponding to the center of spindles and mea-
2) Set the ST into the center of the wheel, and then sure distance " A between marks.
install the wheel alignment gauge. 3) Move the vehicle forward so that the marks line
ST 927380002 ADAPTER up with front sides at height corresponding to the
center of spindles.
4) Measure the distance " 6 between left and the
right marks. Toe-in can then be obtained by the fol-
lowing equation:
A - B = Toe-in

B A

(1) Alignment gauge i i
(2) Turning radius gauge

NOTE:
Refer to the `SPECIFICATIONS' for the caster val-
ues. 1) Loosen the left and right side steering tie-rods
lock nuts.

FS-11
I WHEEL ALIGNMENT
FRONT SUSPENSION

2) Turn the left and right tie rods equal amounts un- 4) Measure the distance "B" between left and right
til the toe-in is at the specification. marks. Toe-in can then be obtained by the follow-
Both the left and right tie-rods are right-hand ing equation:
threaded. To increase toe-in, turn both tie-rods A - B = Toe-in
clockwise equal amounts (as viewed from the in-
side of the vehicle). I

S4M0348A Adjustment
1) Loosen the self-locking nut on inner side of link
(1) Lock nut
rear.
3) Tighten the tie-rod lock nut. CAUTION:
Tightening torque: When loosening or tightening the adjusting
83 N-m (8.5kgf-m, 61.5 ff-lb) bolt, hold the bolt head and turn self-locking
nut.
CAUTION: Discard the loosened self-locking nut and re-
Correct the tie-rod boot, if it is twisted. place with a new one.
NOTE:
Check that the left and right wheel steering angle is
within specifications.
5. REAR WHEEL TOE-IN
Inspection
1) Using a toe-in gauge, measure the rear wheel
toe-in.
Toe-in:
-132 mm (-0.039fo.079 in)
2) Mark the rear sides of left and right tires at height
corresponding to the center of spindles and mea- (1) Adjusting bolt
sure distance "A" between marks. (2) Link rear
3) Move the vehicle forward so the that marks line
up with front sides at height corresponding to the 2) Turn the adjusting bolt head until toe-in is at the
specification.
center of spindles.

FS-12
WHEEL ALIGNMENT I
FRONT SUSPENSION

NOTE:
When the left and right wheels are adjusted for toe-in at the same time, the movement of one scale gradu-
ation 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
~~

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

B4M0352 84M0192

1) Tighten the self-locking nut. Adjus ment
Tightening torque: Turn the tie-rod to adjust the steering angle of both
100 N-m (10.2 kgf-m, 74 ft-lb) inner and outer wheels.
6. STEERING ANGLE CAUTION:
Check the toe-in.
Inspection Correct the boot if it is twisted.
1) Place the vehicle on a turning radius gauge.
2) While depressing the brake pedal, turn the steer-
ing wheel fully to the left and right. With the steer-
ing wheel held at each fully turned position,
-
measure both the inner and outer wheel steering
angle.
Steering angle:
Turbo,sedan and
Model Others
OUTBACK
S4M0348A
I
~~

Outerwheel I 29"35"f1.5" 31"35Y1.5"
(1) Locknut

FS-13
I WHEEL ALIGNMENT
FRONT SUSPENSION

7. THRUST ANGLE 3) When the left and right adjusting bolts are turned
incrementally by one graduation in the same direc-
Inspection
tion, the thrust angle will change approximately 16'
1) Position the vehicle on a level surface. [`I" almost equal to 12 mm (0.472 in)].
is
2) Move the vehicle 3 to 4 meters directly forward.
Thrust angle:
3) Determine the locus of both front and rear axles.
4) Measure the distance "L" between center line of O"f20'
loci of the axles.
Thrust angle:
Less than 20` when "L" is equal to or less
than 15 mm (59 in).

c- .

M S4M0350B

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

T S4M0350B NOTE:
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 the vehicle
(2) Center line of loci (rear axle) body center line. Vehicle is driven straight in the
thrust angle direction while swinging in the oblique
Adjustment direction depending on the degree of the mean
1) Make the thrust angle adjustments by turning thrust angle.
toe-in adjusting bolts of rear suspension equally in (11
the same direction.
2) When one rear wheel is adjusted in a toe-in di-
t
rection, adjust the other rear wheel equally in toe-
out direction, in order to make the thrust angle ad-
justment.

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

FS-14
I WHEEL ALIGNMENT I
FRONT SUSPENSION

Thrust angle: r = (a- p)/2
a: Right rear wheel toe-in angle
p: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitute for a and p in the equation.

B4M01948

(1) Front
(2) Body center line
c.

FS-15
SUB FRAME
FRONT SUSPENSION

3. Sub Frame B: INSTALLATION
Install in the reverse order of removal.
A: REMOVAL
NOTE:
1) Lift-up the vehicle.
Replace the M12 bolt with a new one.
2) Remove the under cover.
3) Remove the bolt cover. Tightening torque:
T1: 34 N.m (3.5 kgf-m, 25 ff-lb)
T2: 55 N-m (5.6 kgf-m, 41 ff-lb)
T3: 71 N.m (7.2 kgf-m, 52 ff-lb)
T4: 105 N-m (10.7 kgf-m, 77 ff-lb)

4) Remove the clip.

(1) M8 bolt
(2) M12 bolt (with max)
(3) M12 bolt (with oil)
(4) M10 bolt

5) Remove the sub frame.
NOTE:
Loosen bolt (1) and leave a few threads caught,
then remove the bolts in the order of (2),(3), (4),
(51,and (6).

FS-16
SUB FRAME
FRONT SUSPENSION

C: INSPECTION
1) Check that there is no damage and distortion at
the sub frame.
2) Check that the bolts are tightened with the spec-
ified torque. If there is looseness, tighten to the
specified torque.
NOTE:
The tightening torque differs by the color for bolt
(3). Always verify the bolt color before checking
tightening torque.
Tightening torque:
T I : 34 N-m (3.5 kgf-m, 25 ff-lb)
T2: 55 N.m (5.6 kgf-m, 41 ff-lb)
T3: 71 N-m (7.2 kgf-m, 52 ff-lb)
T4: Dark green bolt
105 Nom(10.7 kgf-m, 77 ff-lb)
T4: Except dark green bolt
55 N-m (5.6 kgf-m, 41 ff-lb)

FS-17
SUB FRAME
FRONT SUSPENSION

3. Sub Frame B: INSTALLATION
Install in the reverse order of removal.
A: REMOVAL
NOTE:
1) Lift-up the vehicle.
Replace the M12 bolt with a new one.
2) Remove the under cover.
3) Remove the bolt cover. Tightening torque:
T1: 34 N-m (3.5 kgf-my25 ft-16)
T2: 55 N-m (5.6 kgf-my41 ft-16)
T3: 71 N-m (7.2 kgf-my52 ft-16)

4) Remove the clip.

(1) M8 bolt
(2) M12 bolt
(3) MlO bolt

C: INSPECTION
Check that there is no damage and distortion at the
sub frame.

5 ) Remove the sub frame.
NOTE:
Loosen bolt (1) and leave a few threads caught,
(3),
then remove the bolts in the order of (2), (4),
(5), and (6).

FS-16
I
FRONT TRANSVERSE LINK
FRONT SUSPENSION

4. Front Transverse Link B: INSTALLATION
1) Temporarily tighten the two bolts used to secure
A: REMOVAL the rear bushing of the transverse link to body.
1) Set the vehicle on the lift. NOTE:
2) Disconnect the ground terminal from battery. These bolts should be tightened to such an extent
3) Lift-up the vehicle and remove the wheel. that they can still move back and forth in the oblong
4) Remove the sub frame. ing).
5) Disconnect the stabilizer link from transverse
2) Install the bolts used to connect the transverse
link. link to crossmember and temporarily tighten with
6) Remove the bolt securing the ball joint of trans- nut.
verse link to housing.
CAUTION:
Discard the loosened self-locking nut and re-
place with a new one.
3) Insert the ball joint into housing.
4) Connect the stabilizer link to transverse link, and
temporarily tighten bolts.
CAUTION:
Discard the loosened self-locking nut and re-
c.
place with a new one.
S4MOO9(

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

" S4M0090

5) Tighten the following points in the order shown
below when the 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)
9) Extract the ball joint from housing. Except sedan Turbo model:
10) Remove the bolt securing the transverse link to 30 N m (3.1 kgf-m, 22 ft-lb)
crossmember and extract the transverse link from
crossmember. (2) Transverse link and crossmember
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 ff-16)

FS-17
I FRONT TRANSVERSE LINK
FRONT SUSPENSION

NOTE: D: ASSEMBLY
Move the 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.
Unit: mm (in) CAUTION:
Install the front bushing in correct direction, as
.059) shown in the figure.

(1) Rear bushing

6) Install the sub frame.
7) Inspect the wheel alignment and adjust if neces- (1) Face bushing toward center of ball joint
sary. (2) Ball joint

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

G4M0495 I

FS-18
I
FRONT BALL JOINT
FRONT SUSPENSION

5. Front Ball Joint C: INSPECTION
1) Measure the play of ball joint by the following
A: REMOVAL procedures. Replace with a new one when the play
1) Remove the front wheel. exceeds the specified value.
2) Pull out the cotter pin from the ball stud, remove (1) With 686 N (70 kgf, 154 Ib) loaded in the di-
the castle nut, and extract the ball stud from the rection shown in the figure, measure dimension
transverse link. e 1.
3) Remove the bolt securing the ball joint to the
housing.

--4)-xtract the ball joint from the housing.
\
G4M0499

mension e,
- G4M0500

(2) With 686 N (70 kgf, 154 Ib) loaded in the op-
posite direction shown in the figure, measure di-
.
B: INSTALLATION
1) Install the ball joint onto the housing. I 4
Torque (Bolt):
50 N-m (5- kgf-m, 37 ft-lb)
7
CAUTION:
Do not apply grease to the tapered portion of
ball stud.
2) Connect the ball joint to transverse link.
Torque (Castle nut): G4M0501

Sedan turbo model: (3) Calculate plays from the following formula.
30 N-m (3.7 kgf-m, 22ft-lb) S= Q2 - 0 1
Except sedan turbo model: (4) When plays are larger than the following val-
45 N.m (4.6 kgf-m, 33ft-lb) ue, replace with a new one.
3) Retighten the castle nut further within 60" until a FRONT BALL JOINT
slot in castle nut is aligned with the hole in ball stud Specified play for replacement: S
end, then insert the new cotter pin and bend it
Less than 0.3 mm (0.012 in)
around castle nut.
4) Install the front wheel. 2) When the play is smaller than the specified val-
ue, visually 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 a new
ball joint.

FS-19
I FRONT STRUT
FRONT SUSPENSION

6. Front Strut 6) Remove the three nuts securing strut mount to
body.
A: REMOVAL
1) Remove the front wheel.
2) Remove the bolt securing brake hose from strut.

R4Mi78A

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

suo011

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

FS-20
I FRONT STRUT
I
FRONT SUSPENSION

B: INSTALLATION C: DISASSEMBLY
1) Install the strut mount at upper side of strut to 1) Using a coil spring compressor, compress the
body and tighten with nuts. coil spring.
Tightening torque:
20 N-m (2.0 kgf-m, 74.5 ft-lb)
2) Position the aligning mark on camber adjustment
bolt with aligning mark on lower side of strut.
CAUTION:
While holding the head of adjusting bolt,
tighten self-locking nut.
Be sure to use a new self-locking nut.
Tightening torque: S4M0095
775 N-m (77.8 kgf-m, 729 ft-lb)
3 ) Install the ABS sensor harness to strut. 2) Using the ST, remove the self-locking nut.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
33 N.m (3.4 kgf-m, 24.3 ft-lb)
4) Install bolts which secure the brake hose to strut.
-_Tightening torque:
33 N-m (3.4 kgf-m, 24.3 ft-lb)
5 ) Install the front wheels.
NOTE:
Check wheel alignment and adjust if necessary.

3) Remove the strut mount, upper spring seat and
rubber seat from strut.
4) Gradually decreasing the compression force,
and remove the coil spring.
5 ) Remove the dust cover and helper spring.

FS-21
I FRONT STRUT
FRONT SUSPENSION

D: ASSEMBLY 5) Set the coil spring correctly so that its end face
1) Before installing the coil spring, strut mount, etc., fits well into the spring seat as shown.
on the strut, check for the presence of air in the
dampening force generating mechanism of the
strut since air prevents proper dampening force
from being produced.
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-
tips, move the rod up and down. I S4M0353A

(4) If the piston rod moves at least 10 mm (0.39 6) Install the helper and dust cover to the piston
in) in the former step, purge air from the strut. rod.
3) Air purging procedure: 7) Pull the piston rod fully upward, and install the
(1) Place the strut vertically with the piston rod rubber seat and spring seat.
facing up. NOTE:
(2) Fully extend the piston rod. Ensure the upper spring seat is positioned as
(3) With the piston rod fully extended, place the shown in the figure.
-- -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".
4) Using a coil spring compressor, compress the
coil spring.
4 (1)
S4M0097B

NOTE: (1) Outside of body
Make sure that the vertical installing direction of coil
spring is as shown in the figure. 8) Install the strut mount to the piston rod, and tight-
en the self-locking nut temporarily.
CAUTION:
(2 Be sure to use a new self-locking nut.
9) Using a hexagon wrench to prevent strut rod
from turning, tighten self-locking nut with ST.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
55 N.m (5.6 kgf-m, 41 ft-lb)

I B4M0568B I
(1) Fiat (top side)
(2) identificationpaint
(3) inclined (bottom side)

FS-22
I
FRONT STRUT
FRONT SUSPENSION

10) Loosen the coil spring carefully. 5. HELPER
E: INSPECTION Replace it with a new one if cracked or damaged.
Check the disassembled parts for cracks, damage F: DISPOSAL
and wear, and replace with new parts if defective.
CAUTION:
1. DAMPER STRUT On struts which have "GAS FILLED" marked
1) Check for oil leakage. on the outer housing under spring seat, com-
2) Move the piston rod up and down to check that it pletely discharge the gas before disposing, fol-
operates smoothly without any binding. lowing the methods below.
3) Play of piston rod Do not disassemblethe strut damper or place
Measure the play as follows: into a fire.
Fix the outer shell and fully extend the rod. Set a Drill holes before disposing of gas filled
dial gauge at the end of the rod: L [ l o mm (0.39 struts.
in)], then apply a force of W [20 N (2 kgf, 4 Ib)] to Before handling gas filled struts, be sure to
threaded portion. With the force of 20 N (2 kgf, 4 Ib) wear goggles to protect eyes from gas, oil and/
applied, read the dial gauge indication: PI. Apply a or filings.
force of 20 N (2 kgf, 4 Ib) in the opposite direction
of "W", then read the dial gauge indication: P .
,

GAS FILLED
DO NOT OPEN
DO NOT HEAT
I B4M1201

1) Place the gas filled strut on a flat and level sur-
face with piston rod fully extended.
The free play is determined by the following equa- 2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,
tion: make holes in areas shown in the figure.
Play = PI, P2
Limit of play: I piston rod ,-Strut

Less than 0.8 mm (0.031 in)
If the play is greater, replace the strut.
2. STRUT MOUNT
Check the rubber part for creep, cracks and deteri-
oration, and replace it with a new one if defective.
M (1.57 in)

3. DUSTCOVER B4M1202P
If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
One having permanent strain should be replaced
with a new one. When the vehicle posture is un-
even, although there are no considerable reasons
like tire puncture, uneven loading, etc., check the
coil spring for its free length referring to specifica-
tions, cracks, etc., and replace it with a new one if
defective.

FS-23
I FRONT STABILIZER
FRONT SUSPENSION

7. Front Stabilizer B: INSTALLATION
1) Install in the reverse order of removal.
A: REMOVAL NOTE:
Jack-up the front part Of the vehicle
and Install the bushing (on front crossmember side)
it with safety stands (rigid racks). while aligning it with paint mark on stabilizer.
2, Remove the j a c k w plate from lowerpart Of Ensure the bushing and stabilizer have the Same
crossmember. identification colors when installing.
3) Remove the sub frame.
4) Remove the bolt and nut which secure the stabi-
lizer to crossmember.

'' suo012

(1) Mark stamped on stabilizer
c- -
(2) Bushing identification color

5 ) Remove the bolts which Secure the stabilizer link 2)Always tighten the rubber bushing location when
to front transverse link. 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 Nom(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)
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 ( .1 kgf-m, 22 ft-lb)
3
Stabilizer to crossmember:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
3) Install the sub frame.
C: INSPECTION
1) Check the bushing for cracks, fatigue or dam-
age.
2) Check the stabilizer link for deformities, cracks
or damage, and bushing for protrusions from the
hole of stabilizer link.

FS-24
FRONT CROSSMEMBER
FRONT SUSPENSION

8. Front Crossmember 12) Support the crossmember with a jack, remove
the nuts securing crossmember to body and lower
A: REMOVAL crossmember gradually along with the steering
1) Disconnect the ground terminal from battery. gearbox.
2) Lift-up the vehicle and remove the front tires and CAUTION:
wheels. When removing the crossmember downward,
3) Remove the sub frame. fere with SFJ boot.
4) Remove both stabilizer and jack-up plate. 13) Remove the steering gearbox from crossmem-
ber.
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Always tighten the rubber bushing when
wheels are in full contact with the ground and
vehicle is curb weight.
Tightening torque:
Transverse link bushing to crossmember:
c.
100 N.m (10.2 kgf-m, 74 ft-lb)
(1) Front stabilizer Stabilizer to bushing:
(2) Front crossmember 25 N.m (2.5 kgf-m, 18.1 ft-lb)
Tie-rod end to housing:
5) Disconnect the tie-rod end from housing. 27.0 N-m (2.75 kgf-m, 19.9 ft-lb)
6) Remove the front exhaust pipe. (Non-turbo mod- Front cushion rubber to crossmember:
el) Universal joint to pinion shaft:
7 ) Remove the front transverse link from front 24 N-m (2.4 kgf-m, 17.4 ff-16)
crossmember and body. Crossmember to body:
100 N-m (10.2 kgf-m, 74 ft-lb)
2) Purge air from the power steering system.
NOTE:
Check the wheel alignment and adjust if necessary.
C: INSPECTION
Check the crossmember for wear, damage and
cracks, and correct or replace if defective.

8) Remove the nuts attaching engine mount cush-
ion rubber to crossmember.
9) Remove the steering universaljoint.
10) Disconnect the power steering pipe from steer-
ing gear box.
11) Lift the engine by approx. 10 mm (0.39 in) by
using a chain block.

FS-25
I
GENERAL DIAGNOSTIC TABLE
FRONT SUSPENSION

9. General Diagnostic Table
A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible causes Countermeasures

(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.

ning over bump and/or hump.
1) Large rebound shock
3) Large shock in bumping

I Replace.
(1) Breakage of coil spring
(2) Overinflation pressure of tire
I (3) Improper wheel arch height
I Adjust.
I Adjust or replace coil springs with new ones.

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