Subaru FORESTER 2001 Quick Reference Index

Subaru FORESTER 2001 Quick Reference Index

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2001 FORESTER SERVICE MANUAL

BODY 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
G8050GE6

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Summary of Contents for Subaru FORESTER 2001

  • Page 1: Body Section

    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

    GLASS/WINDOWS/MIRRORS Page General Description..................2 Power Window System ................9 Rear Window Defogger System..............19 Windshield Wiper Deicer System..............23 Remote Control Mirror System ..............25 Front Door Glass..................28 Front Regulator and Motor Assembly ............31 Rear Door Glass ..................32 Rear Regulator and Motor Assembly............34 Windshield Glass..................35 Rear Gate Glass ..................38 Rear Quarter Glass ...................39 Roof Window Glass...................41...
  • Page 3: General Description

    GENERAL DESCRIPTION Glass/Windows/Mirrors 1. General Description S905001 A: COMPONENT S905001A05 GW-2...
  • Page 4 GENERAL DESCRIPTION Glass/Windows/Mirrors 1. FIXED GLASS S905001A0506 S5M0497A (1) Windshield glass (5) Side molding (9) Rear gate glass (2) Dam rubber (6) Rear quarter glass (10) Spring (3) Molding (7) Locate pin (4) Rearview mirror mount (8) Rear quarter garnish GW-3...
  • Page 5 GENERAL DESCRIPTION Glass/Windows/Mirrors 2. FRONT DOOR GLASS S905001A0503 S5M0509A (1) Door sash (Front) (5) Motor ASSY Tightening torque: N·m (kgf-m, ft-lb) (2) Glass 7.35 (0.75, 5.4) (3) Door sash (Rear) 14 (1.4, 10.1) (4) Regulator ASSY GW-4...
  • Page 6 GENERAL DESCRIPTION Glass/Windows/Mirrors 3. REAR DOOR GLASS S905001A0504 S5M0510A (1) Door sash (Front) (5) Motor ASSY Tightening torque: N·m (kgf-m, ft-lb) (2) Glass 7.35 (0.75, 5.4) (3) Door sash (Rear) 14 (1.4, 10.1) (4) Regulator ASSY GW-5...
  • Page 7 GENERAL DESCRIPTION Glass/Windows/Mirrors 4. MIRRORS S905001A0505 S5M0457A (1) Outer mirror (3) Mount (5) Mirror (2) Inner rearview mirror (4) Spring GW-6...
  • Page 8 GENERAL DESCRIPTION Glass/Windows/Mirrors B: CAUTION S905001A03 ¼ When electrical connectors are disconnected, always conduct an operational check after con- necting them again. ¼ Avoid impact and damage to the glass. GW-7...
  • Page 9 GENERAL DESCRIPTION Glass/Windows/Mirrors C: PREPARATION TOOL S905001A17 TOOL NAME REMARKS Circuit Tester Used for checking voltage and continuity. Piano Wire Used for window glass removal. Windshield Knife Used for window glass removal. GW-8...
  • Page 10: Power Window System

    POWER WINDOW SYSTEM Glass/Windows/Mirrors 2. Power Window System S905456 A: SCHEMATIC S905456A21 GW-9...
  • Page 11 POWER WINDOW SYSTEM Glass/Windows/Mirrors 1. POWER WINDOW LHD MODEL S905456A2101 SL70-20A GW-10...
  • Page 12 POWER WINDOW SYSTEM Glass/Windows/Mirrors SL70-20B GW-11...
  • Page 13 POWER WINDOW SYSTEM Glass/Windows/Mirrors SL70-20C GW-12...
  • Page 14 POWER WINDOW SYSTEM Glass/Windows/Mirrors SL70-20D GW-13...
  • Page 15 POWER WINDOW SYSTEM Glass/Windows/Mirrors 2. POWER WINDOW RHD MODEL S905456A2102 SR70-20A GW-14...
  • Page 16 POWER WINDOW SYSTEM Glass/Windows/Mirrors SR70-20B GW-15...
  • Page 17 POWER WINDOW SYSTEM Glass/Windows/Mirrors SR70-20C GW-16...
  • Page 18 POWER WINDOW SYSTEM Glass/Windows/Mirrors SR70-20D GW-17...
  • Page 19 POWER WINDOW SYSTEM Glass/Windows/Mirrors B: INSPECTION S905456A10 Symptom Repair order (1) Fuse (SBF-6) (F/B No. 18) (2) Power window circuit breaker All power windows does not operate. (3) Power window relay (4) Wire harness (1) Power window main switch (2) Power window sub switch One window does not operate.
  • Page 20: Rear Window Defogger System

    REAR WINDOW DEFOGGER SYSTEM Glass/Windows/Mirrors 3. Rear Window Defogger System S905455 A: SCHEMATIC S905455A21 GW-19...
  • Page 21 REAR WINDOW DEFOGGER SYSTEM Glass/Windows/Mirrors 1. REAR WINDOW DEFOGGER LHD MODEL S905455A2102 SL52-20 GW-20...
  • Page 22 REAR WINDOW DEFOGGER SYSTEM Glass/Windows/Mirrors 2. REAR WINDOW DEFOGGER RHD MODEL S905455A2103 SR52-20 GW-21...
  • Page 23 REAR WINDOW DEFOGGER SYSTEM Glass/Windows/Mirrors B: INSPECTION S905455A10 Symptom Repair order (1) Fuse (M/B No. 1) (2) Rear defogger relay (3) Defogger switch Rear window defogger does not operate. (4) Rear defogger condenser (5) Deffogger wire (6) Wire harness GW-22...
  • Page 24: Windshield Wiper Deicer System

    WINDSHIELD WIPER DEICER SYSTEM Glass/Windows/Mirrors 4. Windshield Wiper Deicer System S905457 A: SCHEMATIC S905457A21 1. WINDSHIELD WIPER DEICER S905457A2101 SG78-20 GW-23...
  • Page 25 WINDSHIELD WIPER DEICER SYSTEM Glass/Windows/Mirrors B: INSPECTION S905457A10 Symptom Repair order (1) Fuse (F/B No. 18, 19) (2) Wiper deicer relay Wiper deicer does not operate. (3) Wiper deicer switch (4) Wire harness GW-24...
  • Page 26: Remote Control Mirror System

    REMOTE CONTROL MIRROR SYSTEM Glass/Windows/Mirrors 5. Remote Control Mirror System S905458 A: SCHEMATIC S905458A21 1. REMOTE CONTROL MIRROR LHD MODEL S905458A2102 SL79-20 GW-25...
  • Page 27 REMOTE CONTROL MIRROR SYSTEM Glass/Windows/Mirrors 2. REMOTE CONTROL MIRROR RHD MODEL S905458A2103 SR79-20 GW-26...
  • Page 28 REMOTE CONTROL MIRROR SYSTEM Glass/Windows/Mirrors B: INSPECTION S905458A10 Symptom Repair order (1) Fuse (F/B No. 4) All function does not operate. (2) Mirror switch (3) Wire harness (1) Mirror switch One side of the mirror motor does not operate. (2) Mirror motor (3) Wire harness (1) Mirror switch Mirror heater does not operate.
  • Page 29: Front Door Glass

    FRONT DOOR GLASS Glass/Windows/Mirrors 6. Front Door Glass 7) Operate the power window switch to move S905452 glass to the position shown in the figure, and then A: REMOVAL remove the two nuts from service holes. S905452A18 1) Remove door trim. <Ref. to EI-26, REMOVAL, Front Door Trim.>...
  • Page 30 FRONT DOOR GLASS Glass/Windows/Mirrors 5) For adjustment of upper and lower ends of cen- C: ADJUSTMENT S905452A01 ter pillar, loosen adjusting nut (A). NOTE: Before adjustment, ensure that all adjusting bolts of stabilizer, upper stopper, and sash are loose and door glass is raised so that it is in contact with weatherstrip.
  • Page 31 FRONT DOOR GLASS Glass/Windows/Mirrors 8) After stabilizer adjustment, carry out glass 11) After adjustments, tighten nuts. 12) After adjustment of glass, if there is a gap crimp adjustment. First, visually ensure positional between outer lip of gusset and glass surface, relationship between retainer &...
  • Page 32: Front Regulator And Motor Assembly

    FRONT REGULATOR AND MOTOR ASSEMBLY Glass/Windows/Mirrors 7. Front Regulator and Motor Assembly S905449 A: REMOVAL S905449A18 1) Remove door trim. <Ref. to EI-26, REMOVAL, Front Door Trim.> 2) Remove sealing cover. <Ref. to EB-13, REMOVAL, Front Sealing Cover.> 3) Remove inner remote.
  • Page 33: Rear Door Glass

    REAR DOOR GLASS Glass/Windows/Mirrors 8. Rear Door Glass B: INSTALLATION S905450A11 S905450 1) Install in the reverse order of removal. A: REMOVAL S905450A18 CAUTION: 1) Remove door trim. <Ref. to EI-27, REMOVAL, Make sure that glass stay is placed securely in Rear Door Trim.>...
  • Page 34 REAR DOOR GLASS Glass/Windows/Mirrors wear of weatherstrip. Be careful when adjust- ing. ¼ After adjustment, move glass up and down to check whether it is caught. GW-33...
  • Page 35: Rear Regulator And Motor Assembly

    REAR REGULATOR AND MOTOR ASSEMBLY Glass/Windows/Mirrors 9. Rear Regulator and Motor B: INSTALLATION S905451A11 Assembly 1) Install in the reverse order of removal. S905451 2) Adjust rear door glass. <Ref. to GW-32, A: REMOVAL ADJUSTMENT, Rear Door Glass.> S905451A18 1) Remove door trim. <Ref. to EI-27, REMOVAL, C: INSPECTION Rear Door Trim.>...
  • Page 36: Windshield Glass

    WINDSHIELD GLASS Glass/Windows/Mirrors 10. Windshield Glass S905448 A: REMOVAL S905448A18 1. USING WINDSHIELD KNIFE S905448A1801 1) Remove cowl panel. <Ref. to EI-25, REMOVAL, Cowl Panel.> 2) Remove front side molding and upper front molding. 3) Tape body side of the circumference of wind- G5M0412 shield glass for protection.
  • Page 37 WINDSHIELD GLASS Glass/Windows/Mirrors 9) Apply primer to adhesive layer of body. B: INSTALLATION S905448A11 CAUTION: 1) Clean external circumference of windshield ¼ Primer once attached to the painted surface glass with alcohol or white gasoline. of the body and internal trim is hard to wipe off. 2) Remove adhesive layer on the body using cut- Mask the circumference of such areas.
  • Page 38 WINDSHIELD GLASS Glass/Windows/Mirrors 14) Remove adhesive overflowing from outside of glass until it becomes level with outer height of glass. Then, add adhesive to portions that need it, and clean with alcohol or white gasoline. G5M0496 15) First, press-fit upper front window molding and last, roof molding.
  • Page 39: Rear Gate Glass

    REAR GATE GLASS Glass/Windows/Mirrors 11. Rear Gate Glass 2) Install glass in the same procedure as for wind- S905376 shield glass. <Ref. to GW-36, INSTALLATION, A: REMOVAL Windshield Glass.> S905376A18 1) Remove real wiper motor. <Ref. to WW-20, REMOVAL, Rear Wiper Motor.> 2) Remove electrical connector from rear defog- ger terminal.
  • Page 40: Rear Quarter Glass

    REAR QUARTER GLASS Glass/Windows/Mirrors 12. Rear Quarter Glass S905453 A: REMOVAL S905453A18 1) Remove rear quarter molding on corner. 2) Remove glass in the same procedure as for windshield glass. <Ref. to GW-35, REMOVAL, Windshield.> S5M0388A B: INSTALLATION 7) Apply primer to surface of body to be adhered. S905453A11 CAUTION: 1) Using a putty knife, etc., cut layer of adhesive...
  • Page 41 REAR QUARTER GLASS Glass/Windows/Mirrors 12) Mount glass on body with matching pins (A) aligned. S5M0211B 13) Attach quickly and press all sides lightly. CAUTION: ¼ When door is opened/closed after glass is bonded, always lower door glass and then open/close it carefully. ¼...
  • Page 42: Roof Window Glass

    ROOF WINDOW GLASS Glass/Windows/Mirrors 13. Roof Window Glass S905339 A: REMOVAL S905339A18 <Ref. to SR-7, REMOVAL, Sunroof Lid.> B: INSTALLATION S905339A11 <Ref. to SR-7, INSTALLATION, Sunroof Lid.> C: ADJUSTMENT S905339A01 <Ref. to SR-7, ADJUSTMENT, Sunroof Lid.> GW-41...
  • Page 43: Inner Rearview Mirror

    INNER REARVIEW MIRROR Glass/Windows/Mirrors 14. Inner Rearview Mirror S905340 A: REMOVAL S905340A18 NOTE: The spring cannot be reused. Prepare a new spring before removal. 1) Turn mirror base 90 degrees clockwise or coun- terclockwise to remove it. B5M1059 2) Remove spring from mirror base. B5M1060 CAUTION: Be careful not to damage the mirror surface.
  • Page 44: Power Window Control Switch

    POWER WINDOW CONTROL SWITCH Glass/Windows/Mirrors 15. Power Window Control 2. SUB-SWITCH S903621A1802 Switch 1) Remove door trim. <Ref. to EI-27, REMOVAL, S905621 Rear Door Trim.> A: REMOVAL 2) Remove screws and sub-switch. S903621A18 1. MAIN SWITCH S903621A1801 1) Release two hooks (A) of switch panel to remove power window main switch.
  • Page 45 POWER WINDOW CONTROL SWITCH Glass/Windows/Mirrors Rear left switch: Switch position Tester connection Specified condition 12 — 9, 10 — 7 Continuity 9 — 10 — 7 Continuity DOWN 12 — 10, 9 — 7 Continuity Rear right switch: Switch position Tester connection Specified condition 12 —...
  • Page 46 POWER WINDOW CONTROL SWITCH Glass/Windows/Mirrors 4. SUB-SWITCH (REAR) S903621A1006 Check continuity between connector terminals. Rear door switch: Switch position Tester connection Specified condition 6 — 5, 1 — 4 Continuity 1 — 4, 2 — 5 Continuity DOWN 6 — 4, 2 — 5 Continuity If NG, replace the sub-switch.
  • Page 47: Rear Window Defogger Switch

    REAR WINDOW DEFOGGER SWITCH Glass/Windows/Mirrors 16. Rear Window Defogger Switch S905559 A: REMOVAL S905559A18 1) Remove center air vent grille. <Ref. to AC-41, REMOVAL, Air Vent Grille.> 2) Pull out switch and disconnect the connector. S5M0495 B: INSTALLATION S905559A11 Install in the reverse order of removal. GW-46...
  • Page 48 REAR WINDOW DEFOGGER SWITCH Glass/Windows/Mirrors C: INSPECTION S905559A10 1) Turn ignition switch ON. 2) Check continuity between terminals on the wire harness side with connectors connected. Connector & terminal (i18) No. 6 (+) — No. 8 (−): S5M0514A IGN SW Switch position Tester connection Specified condition...
  • Page 49: Rear Window Defogger

    REAR WINDOW DEFOGGER Glass/Windows/Mirrors 17. Rear Window Defogger B: REPAIR S905341A11 S905341 1) Clean broken portion with alcohol or white A: INSPECTION S905341A10 gasoline. CAUTION: 2) Mask both side of wire with thin film. When wiping stain on glass off with cloth, use 3) Apply conductive silver composition (DUPONT a dry and soft cloth and move it in the direction No.
  • Page 50: Outer Mirror Assembly

    OUTER MIRROR ASSEMBLY Glass/Windows/Mirrors 18. Outer Mirror Assembly S905338 A: REMOVAL S905338A18 1) Remove door trim. <Ref. to EI-26, REMOVAL, Front Door Trim.> 2) Pull off sealing cover to disconnect mirror elec- trical connector. B5M1054 3) Loosen screws to remove mirror assembly. B5M1055 B: INSTALLATION S905338A11...
  • Page 51 OUTER MIRROR ASSEMBLY Glass/Windows/Mirrors C: INSPECTION S905338A10 Check to ensure that rearview mirror moves prop- erly when battery voltage is applied to terminals. Mirror heater not-equipped model: Switch position Terminal connection — 1 (+) — 3 (−) DOWN 3 (+) — 1 (−) LEFT 2 (+) —...
  • Page 52: Outer Mirror

    OUTER MIRROR Glass/Windows/Mirrors 19. Outer Mirror S905658 A: REPLACEMENT S905658A20 1) Remove the door mirror assembly. <Ref. to GW-49, REMOVAL, Outer Mirror Assembly.> 2) Warm the area around the mirror holder with a hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier.) 3) Use a flat-bladed screwdriver without sharp...
  • Page 53 REMOTE CONTROL MIRROR SWITCH Glass/Windows/Mirrors 20. Remote Control Mirror Switch S905342 A: REMOVAL S905342A18 Using a thin flat-bladed screwdriver, remove the switch and disconnect the connector. S5M0496 B: INSTALLATION S905342A11 Install in the reverse order of removal. GW-52...
  • Page 54: Remote Control Mirror Switch

    REMOTE CONTROL MIRROR SWITCH Glass/Windows/Mirrors C: INSPECTION S905342A10 Move rearview mirror switch to each position and check continuity between terminals. B5M1132 Change over switch left position: Switch position Tester connection Specified condition NEUTRAL All terminals No continuity 7 — 4, 2 — 1 Continuity DOWN 7 —...
  • Page 55: Wiper Deicer

    WIPER DEICER Glass/Windows/Mirrors 21. Wiper Deicer S905622 A: INSPECTION S905622A10 Refer to INSPECTION under Rear Window Defog- ger. <Ref. to GW-48, INSPECTION, Rear Window Defogger.> B: REPAIR S905622A11 Refer to REPAIR under Rear Window Defogger. <Ref. to GW-48, REPAIR, Rear Window Defogger. GW-54...
  • Page 56: Wiper Deicer Switch

    WIPER DEICER SWITCH Glass/Windows/Mirrors 22. Wiper Deicer Switch S905623 A: REMOVAL S905623A18 1) Remove lower cover. 2) Disconnect the connector and remove the switch. S5M0044A B: INSTALLATION S905623A11 Install in the reverse order of removal. C: INSPECTION S905623A10 Move wiper deicer switch to each position and check continuity between terminals.
  • Page 57 WIPER DEICER SWITCH Glass/Windows/Mirrors MEMO: GW-56...

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