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Subaru forester 2001 Service Manual

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2001 FORESTER SERVICE MANUAL
ENGINE2 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 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.
QUICK REFERENCE INDEX
G8050GE3

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Summary of Contents for Subaru forester 2001

  • Page 1 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.

  • Page 2: Table Of Contents

    EXHAUST EX(DOHC TURBO) Page General Description..................2 Front Exhaust Pipe..................7 Center Exhaust Pipe ...................9 Joint Pipe....................13 Rear Exhaust Pipe ..................14 Muffler......................15...

  • Page 3: General Description

    GENERAL DESCRIPTION Exhaust 1. General Description S182001 A: COMPONENT S182001A05 1. FRONT EXHAUST PIPE S182001A0501 S2M2237A EX(DOHC TURBO)-2...
  • Page 4 GENERAL DESCRIPTION Exhaust (1) Gasket (11) Front exhaust pipe lower insula- (21) Turbocharger joint pipe (2) Upper exhaust manifold cover tor (RH) (22) Gasket (RH) (12) Front exhaust pipe lower insula- (23) Front oxygen (A/F) sensor (3) Exhaust manifold (RH) tor (LH) (24) Precatalytic converter (4) Lower exhaust manifold cover...
  • Page 5 GENERAL DESCRIPTION Exhaust 2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER S182001A0502 ¼ AUSTRALIA SPEC. VEHICLES S2M2239A (1) Gasket (10) Lower cover (19) Muffler cutter (2) Rear oxygen converter (11) Upper cover A (3) Upper center pipe cover (12) Lower cover A Tightening torque: N·m (kgf-m, ft-lb) (4) Center exhaust pipe (13) Spring...
  • Page 6 GENERAL DESCRIPTION Exhaust ¼ EXCEPT AUSTRALIA SPEC. VEHICLES S2M2176B (1) Gasket (14) Rear catalytic converter (25) Upper rear exhaust pipe cover (2) Front catalytic converter (15) Upper clamp (Rear) (3) Upper center pipe cover (Front) (16) Gasket (26) Gasket (4) Center exhaust pipe (Front) (17) Rear exhaust pipe (27) Muffler (5) Lower center pipe cover (Front)
  • Page 7 GENERAL DESCRIPTION Exhaust B: CAUTION S182001A03 ¼ Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. ¼ Remove contamination including dirt and corro- sion before removal, installation or disassembly. ¼ Keep the disassembled parts in order and pro- tect them from dust or dirt.

  • Page 8: Front Exhaust Pipe

    FRONT EXHAUST PIPE Exhaust 2. Front Exhaust Pipe 10) Separate front exhaust pipe from exhaust S182065 mani-folds. A: REMOVAL S182065A18 1) Disconnect battery ground cable. G2M0854 B: INSTALLATION G6M0095 S182065A11 2) Remove front oxygen (A/F) sensor. <Ref. to CAUTION: FU(DOHC TURBO)-42, REMOVAL, Front Oxygen Replace gaskets with new ones.
  • Page 9 FRONT EXHAUST PIPE Exhaust 5) Connect exhaust manifold (RH) to turbocharger joint pipe. Tightening torque: 35 N·m (3.6 kgf-m, 26.0 ft-lb) G2M0853 6) Install upper and lower exhaust manifold covers (LH). Tightening torque: 18.6 N·m (1.9 kgf-m, 13.7 ft-lb) 7) Install lower exhaust manifold cover (RH). Tightening torque: 18.6 N·m (1.9 kgf-m, 13.7 ft-lb) G2M0852...

  • Page 10: Center Exhaust Pipe

    CENTER EXHAUST PIPE Exhaust 3. Center Exhaust Pipe 8) Remove bolts which install the lower side of S182067 turbocharger upper cover. A: REMOVAL S182067A18 CAUTION: Be careful, turbocharger and exhaust pipe are 1) Set the vehicle on the lift. hot. 2) Disconnect battery ground cable.
  • Page 11 CENTER EXHAUST PIPE Exhaust 12) Separate center exhaust pipe from turbo- 17) Remove intercooler bracket. charger. 18) Remove bolt which holds center exhaust pipe to hanger bracket. CAUTION: Be careful not to pull down center exhaust pipe. H2M1745 13) Lift-up the vehicle. 14) Disconnect connector from rear oxygen sen- sor.
  • Page 12 CENTER EXHAUST PIPE Exhaust 4) Install center exhaust pipe to rear exhaust pipe. 7) Tighten bolt which holds center exhaust pipe to hanger bracket. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) Tightening torque: 35 N·m (3.6 kgf-m, 26 ft-lb) G2M0855 S2M1723 5) Connect connector to rear oxygen sensor.
  • Page 13 CENTER EXHAUST PIPE Exhaust 13) Tighten bolts which install the under side of 17) Install intercooler bracket. turbocharger upper cover. Tightening torque: 7.4 N·m (0.75 kgf-m, 5.4 ft-lb) S2M1928 18) Install intercooler. <Ref. IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 19) Align center of roll connector. (With airbag H2M1929 model) <Ref.

  • Page 14: Joint Pipe

    JOINT PIPE Exhaust 4. Joint Pipe 6) Remove lower exhaust manifold cover (RH). S182771 A: REMOVAL S182771A18 1) Disconnect battery ground cable. G2M0852 7) Remove nuts. Which hold front exhaust mani- fold to joint pipe. G6M0095 2) Remove solenoid valve cover. EN0917 8) Remove center...

  • Page 15: Rear Exhaust Pipe

    REAR EXHAUST PIPE Exhaust 5. Rear Exhaust Pipe B: INSTALLATION S182068A11 S182068 CAUTION: A: REMOVAL S182068A18 Replace gaskets with new ones. 1) Disconnect battery ground cable. 1) Install rear exhaust pipe to muffler. Tightening torque: 48 N·m (4.9 kgf-m, 35.4 ft-lb) G6M0095 2) Lift up the vehicle.

  • Page 16: Muffler

    NOTE: 2) Make sure there are no holes or rusting. To facilitate removal, apply a coat of SUBARU 3) Make sure the cushion rubber is not worn or CRC to mating area of rubber cushions in cracked.
  • Page 17 MUFFLER Exhaust MEMO: EX(DOHC TURBO)-16...