Subaru 2001 Forester Bedienungsanleitung

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, reassem-

bling, inspection and adjustment of com-

ponents 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 genu-

ine parts.

All information, illustration and specifica-

tions contained in this manual are based

on the latest product information avail-

able at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.

2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

G8050GE5

POWER ASSISTED SYSTEM (POWER

STEERING) PS

Page

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

2. Steering Wheel..........................................................................................27

3. Universal Joint...........................................................................................28

4. Tilt Steering Column..................................................................................30

5. Steering Gearbox [LHD Model].................................................................33

6. Steering Gearbox [RHD Model]................................................................53

7. Pipe Assembly...........................................................................................78

8. Oil Pump....................................................................................................93

9. Reservoir Tank ........................................................................................100

10. Power Steering Fluid...............................................................................101

11. General Diagnostic Table........................................................................103

1. General Description S601001

A: SPECIFICATIONS S601001E49

Model LHD RHD

Steering wheel Free play mm (in) 17 (0.67)

Turning angle Inner tire & wheel 34.4°±1.5°

Outer tire & wheel 30.2°±1.5°

Steering shaft Clearance between steering

wheel and column cover mm (in) 3.0 (0.118)

Steering gearbox

(Power steering

system)

Sliding resistance N (kgf, lb) 304.0 (31.0, 68.4) or less

Rack

shaft play

in radial

direction

Right-turn

steering mm (in) 0.15 (0.0059) or less

Horizontal movement:

0.6 (0.024) or less

Vertical movement:

0.4 (0.016) or less

Left-turn

steering mm (in)

Horizontal movement:

0.3 (0.012) or less

Vertical movement:

0.15 (0.0059) or less

0.4 (0.016) or less

Input

shaft play

In radial

direction mm (in) 0.18 (0.0071) or less

In axial

direction mm (in) 0.1 (0.004) or less

Turning resistance N (kgf, lb) Within 30 mm (1.18 in) from rack center in straight

ahead position: Less than 11.18 (1.14, 2.51)

Maximum allowable value: 12.7 (1.3, 2.9)

Oil pump

[Non-turbo model

(Power steering

system)]

Pulley

shaft Radial play mm (in) 0.4 (0.016) or less

Axial play mm (in) 0.9 (0.035) or less

Pulley Ditch deflection mm (in) 1.0 (0.039) or less

Resistance to

rotation N (kgf, lb) 9.22 (0.94, 2.07) or less

Regular pressure kPa (kg/cm

, psi) 981 (10, 142) or less

Relief pressure kPa (kg/cm

, psi) 7,355 (75, 1,067)

Oil pump

[Turbo model

(Power steering

system)]

Pulley

shaft Radial play mm (in) 0.4 (0.016) or less

Axial play mm (in) 0.6 (0.024) or less

Pulley Ditch deflection mm (in) 1.0 (0.039) or less

Resistance to

rotation N (kgf, lb) 9.22 (0.94, 2.07) or less

Regular pressure kPa (kg/cm

, psi) 981 (10, 142) or less

Relief pressure kPa (kg/cm

, psi) 9,807 (100, 1,422)

Steering wheel

effort

(Power steering

system)

At standstill with engine

idling on a concrete road N (kgf, lb) 29.4 (3.0, 6.6) or less

At standstill with engine

stalled on a concrete road N (kgf, lb) 294.2 (30, 66.2) or less

Recommended power steering fluid Manufacturer

ATF DEXRON IIE or III

B.P.

CALTEX

CASTROL

MOBIL

SHELL

TEXACO

PS-2

GENERAL DESCRIPTION

Power Assisted System (Power Steering)

Model Non-turbo Turbo

Whole system

Minimum turning radius m (ft) 5.4 (17.7)

Steering angle (Inside-Outside) 34.4°±1.5°—30.2°±1.5°

Steering wheel diameter mm (in) With AIRBAG: 385 (15.16)

Without AIRBAG: 385 (15.16)

Overall gear ratio (Turns, lock to lock) LHD: 19.0 (3.4)

RHD: 16.7 (3.0)

Gearbox Type Rack and pinion, Integral

Backlash 0 (Automatically adjustable)

Valve (Power steering system) Rotary valve

Pump

(Power steering

system)

Type Vane pump

Oil tank Installed on pump

Output cm

(cu in)/

rev. 7.2 —0.6 (0.439 —0.037) 9.6 —0.65 (0.586—0.040)

Relief pressure kPa (kg/cm

psi) 7,355 (75, 1,067) 7,846 (80, 1,138)

Hydraulic fluid control Drooping in response to increased engine revolutions

Hydraulic fluid (US qt, Imp

qt) 1,000 rpm: 7 (7.4, 6.2)

3,000 rpm: 5 (5.3, 4.4)

Range of revolution rpm 500 —7,500 500 —8,000

Revolving direction Clockwise

Working fluid

(Power steering

system)

Name ATF DEXRON IIE or III

Capacity

Oil tank (US qt, Imp

qt) 0.3 (0.3, 0.3)

Total (US qt, Imp

qt) 0.7 (0.7, 0.6)

CAUTION:

This table lists various clearances that must be

correctly adjusted to ensure normal vehicle

driving without interfering noise, or any other

faults.

Location Minimum allowance

(1) Crossmember —Pipe 5 mm (0.20 in)

(2) DOJ —Shaft or joint 14 mm (0.55 in)

(3) DOJ —Valve housing 11 mm (0.43 in)

(4) Pipe —Pipe 2 mm (0.08 in)

(5) Stabilizer —Pipe 5 mm (0.20 in)

(6) Exhaust pipe —Pipe 15 mm (0.59 in)

(7) Exhaust pipe —Gearbox bolt 15 mm (0.59 in)

(8) Side frame —Hose A and B 15 mm (0.59 in)

(9) Cruise control pump —Hose A and B 15 mm (0.59 in)

(10) Pipe portion of hose A —Pipe portion of hose B 1.5 mm (0.059 in)

(11) AT cooling hose —Joint (LHD model) 20 mm (0.79 in)

PS-3

GENERAL DESCRIPTION

Power Assisted System (Power Steering)

쐌Non-turbo model

S4M0172A

쐌Turbo model

S4M0565A

PS-4

GENERAL DESCRIPTION

Power Assisted System (Power Steering)

B: COMPONENT S601001A05

1. STEERING WHEEL AND COLUMN S601001A0501

쐌With Airbag Model

S4M0304B

(1) Bushing

(2) Steering shaft

(3) Knee protector

(4) Steering roll connector

(5) Column cover

(6) Steering wheel

(7) Airbag module Tightening torque: N·m (kgf-m, ft-lb)

T1: 1.2 (0.12, 0.9)

T2: 3.4 (0.35, 2.5)

T3: 25 (2.5, 18.1)

T4: 44 (4.5, 32.5)

PS-5

GENERAL DESCRIPTION

Power Assisted System (Power Steering)

쐌Without Airbag Model

S4M0311A

(1) Bushing

(2) Steering shaft

(3) Knee protector

(4) Combination switch

(5) Column cover

(6) Steering wheel

(7) Pad ASSY Tightening torque: N·m (kgf-m, ft-lb)

T1: 1.2 (0.12, 0.9)

T2: 3.4 (0.35, 2.5)

T3: 25 (2.5, 18.1)

T4: 44 (4.5, 32.5)

PS-6

GENERAL DESCRIPTION

Power Assisted System (Power Steering)

MEMO:

PS-7

GENERAL DESCRIPTION

Power Assisted System (Power Steering)

2. POWER ASSISTED SYSTEM FOR NON-TURBO MODEL S601001A0504

쐌LHD Model

S4M0175E

PS-8

GENERAL DESCRIPTION

Power Assisted System (Power Steering)

(1) Eye bolt

(2) Pipe C

(3) Gasket

(4) Clip

(5) Pipe D

(6) Clamp E

(7) O-ring

(8) Cap

(9) Strainer

(10) Upper shell

(11) Buffle

(12) Seal washer

(13) Lower shell

(14) Pulley

(15) Oil pump

(16) Bracket

(17) Belt tension nut

(18) Bushing

(19) Belt cover

(20) Pipe E

(21) Pipe F

(22) Clamp plate

(23) Universal joint

(24) Dust cover

(25) Valve housing

(26) Gasket

(27) Oil seal

(28) Special bearing

(29) Seal ring

(30) Pinion and valve ASSY

(31) Oil seal

(32) Back-up washer

(33) Ball bearing

(34) Snap ring

(35) Lock nut

(36) Adjusting screw

(37) Spring

(38) Sleeve

(39) Adapter

(40) Clamp

(41) Cotter pin

(42) Castle nut

(43) Dust seal

(44) Clip

(45) Tie-rod end

(46) Clip

(47) Boot

(48) Band

(49) Tie-rod

(50) Lock washer

(51) Pipe B

(52) Pipe A

(53) Steering body

(54) Oil seal

(55) Piston ring

(56) Rack

(57) Rack bushing

(58) Rack stopper

(59) Circlip

Tightening torque: N·m (kgf-m, ft-lb)

T1: 6 (0.6, 4.3)

T2: 7.4 (0.75, 5.4)

T3: 8 (0.8, 5.8)

T4: 13 (1.3, 9.4)

T5: 15 (1.5, 10.8)

T6: 18 (1.8, 13.0)

T7: 22 (2.2, 15.9)

T8: 24 (2.4, 17.4)

T9: 25 (2.5, 18.1)

T10: 27.0 (2.75, 19.9)

T11: 39 (4.0, 28.9)

T12: 52 (5.3, 38)

T13: 59 (6.0, 43)

T14: 78 (8.0, 58)

T15: 83 (8.5, 61.5)

PS-9

GENERAL DESCRIPTION

Power Assisted System (Power Steering)

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