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Subaru 2001 FORESTER Service Manual

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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 2001 FORESTER

  • 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

    LIGHTING SYSTEM Page General Description..................2 Headlight and Tail Light System ..............4 Front Fog Light System................14 Rear Fog Light System ................18 Turn Signal and Hazard Light System ............22 Back-up Light System ................28 Stop Light System ..................30 Interior Light System .................32 Headlight Beam Leveler System...............38 Combination Switch (Light) ...............40 Headlight Assembly...................42 Headlight Bulb ...................44...

  • Page 3: General Description

    GENERAL DESCRIPTION Lighting System 1. General Description A: SPECIFICATIONS S914001E49 S914001 Headlight 12 V — 60 W/55 W (Halogen) Front turn signal light 12 V — 21 W Side turn signal light 12 V — 5 W Parking light 12 V — 5 W Front fog light 12 V —...
  • Page 4 GENERAL DESCRIPTION Lighting System MEMO: LI-3...

  • Page 5: Headlight And Tail Light System

    HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System 2. Headlight and Tail Light System S914415 A: SCHEMATIC S914415A21 1. HEADLIGHT LHD MODEL S914415A2104 SL19-20 LI-4...
  • Page 6 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System 2. HEADLIGHT RHD MODEL S914415A2105 SR19-20 LI-5...
  • Page 7 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System 3. CLEARANCE LIGHT AND ILLUMINATION LIGHT LHD MODEL S914415A2106 SL21-20A LI-6...
  • Page 8 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System SL21-20B LI-7...
  • Page 9 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System SL21-20C LI-8...
  • Page 10 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System 4. CLEARANCE LIGHT AND ILLUMINATION LIGHT RHD MODEL S914415A2107 SR21-20A LI-9...
  • Page 11 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System SR21-20B LI-10...
  • Page 12 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System SR21-20C LI-11...
  • Page 13 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System B: INSPECTION S914415A10 1. HEADLIGHT RELAY S914415A1001 Check continuity between terminals when terminal No. 4 is connected to battery and terminal No. 3 is grounded. When current Between terminals Continuity exists. flows. No. 1 and No. 2 Between terminals Continuity does not No.
  • Page 14 HEADLIGHT AND TAIL LIGHT SYSTEM Lighting System MEMO: LI-13...

  • Page 15: Front Fog Light System

    FRONT FOG LIGHT SYSTEM Lighting System 3. Front Fog Light System S914473 A: SCHEMATIC S914473A21 1. FRONT FOG LIGHT LHD MODEL S914473A2105 SL22-20 LI-14...
  • Page 16 FRONT FOG LIGHT SYSTEM Lighting System 2. FRONT FOG LIGHT RHD MODEL S914473A2106 SR22-20 LI-15...
  • Page 17 FRONT FOG LIGHT SYSTEM Lighting System B: INSPECTION S914473A10 1. FRONT FOG LIGHT SWITCH S914473A1001 B6M1583 Check continuity between terminals when operat- ing the switch. Specified condi- Switch position Tester connection tion — No continuity 3 - 5 - 6 Continuity 2.
  • Page 18 FRONT FOG LIGHT SYSTEM Lighting System MEMO: LI-17...

  • Page 19: Rear Fog Light System

    REAR FOG LIGHT SYSTEM Lighting System 4. Rear Fog Light System S914476 A: SCHEMATIC S914476A21 1. REAR FOG LIGHT LHD MODEL S914476A2102 SL30-20 LI-18...
  • Page 20 REAR FOG LIGHT SYSTEM Lighting System 2. REAR FOG LIGHT RHD MODEL S914476A2103 SR30-20 LI-19...
  • Page 21 REAR FOG LIGHT SYSTEM Lighting System B: INSPECTION S914476A10 1. REAR FOG LIGHT SWITCH S914476A1001 1) Turn ignition switch ON. 2) Turn on the headlight or front fog light. 3) Push the rear fog light switch and check if the rear fog light turns on.
  • Page 22 REAR FOG LIGHT SYSTEM Lighting System MEMO: LI-21...

  • Page 23: Turn Signal And Hazard Light System

    TURN SIGNAL AND HAZARD LIGHT SYSTEM Lighting System 5. Turn Signal and Hazard Light System S914481 A: SCHEMATIC S914481A21 LI-22...
  • Page 24 TURN SIGNAL AND HAZARD LIGHT SYSTEM Lighting System 1. TURN SIGNAL LIGHT AND HAZARD LIGHT LHD MODEL S914481A2102 SL26-20A LI-23...
  • Page 25 TURN SIGNAL AND HAZARD LIGHT SYSTEM Lighting System SL26-20B LI-24...
  • Page 26 TURN SIGNAL AND HAZARD LIGHT SYSTEM Lighting System 2. TURN SIGNAL LIGHT AND HAZARD LIGHT RHD MODEL S914481A2103 SR26-20A LI-25...
  • Page 27 TURN SIGNAL AND HAZARD LIGHT SYSTEM Lighting System SR26-20B LI-26...
  • Page 28 TURN SIGNAL AND HAZARD LIGHT SYSTEM Lighting System B: INSPECTION S914481A10 1. TURN SIGNAL SWITCH S914481A1001 <Ref. to LI-40 REMOVAL, Combination Switch (Light).> 2. HAZARD SWITCH S914481A1002 B6M1483 Check continuity between terminals when operat- ing the switch. Specified condi- Switch position Tester connection tion 6 - 7...

  • Page 29: Back-Up Light System

    BACK-UP LIGHT SYSTEM Lighting System 6. Back-up Light System S914414 A: SCHEMATIC S914414A21 1. BACK-UP LIGHT S914414A2101 SG29-20 LI-28...
  • Page 30 BACK-UP LIGHT SYSTEM Lighting System B: INSPECTION S914414A10 1. BACK-UP LIGHT SWITCH (M/T) S914414A1001 Check continuity between terminals. Specified condi- Switch position Tester connection tion When shift lever Turbo engine is set in reverse Continuity model: 2 - 4 position Non-turbo engine model: 1 - 2 Other positions...

  • Page 31: Stop Light System

    STOP LIGHT SYSTEM Lighting System 7. Stop Light System S914417 A: SCHEMATIC S914417A21 1. STOP LIGHT S914417A2103 SG25-20 LI-30...
  • Page 32 STOP LIGHT SYSTEM Lighting System B: INSPECTION S914417A10 1. STOP LIGHT SWITCH S914417A1001 S6M0570A Check continuity between terminals. Specified condi- Switch position Tester connection tion When brake pedal 1 - 2: Without Continuity is depressed cruise control 2 - 3: With cruise When brake pedal No continuity control...

  • Page 33: Interior Light System

    INTERIOR LIGHT SYSTEM Lighting System 8. Interior Light System S914418 A: SCHEMATIC S914418A21 1. INTERIOR LIGHT LHD MODEL S914418A2102 SL24-20A LI-32...
  • Page 34 INTERIOR LIGHT SYSTEM Lighting System SL24-20B LI-33...
  • Page 35 INTERIOR LIGHT SYSTEM Lighting System 2. INTERIOR LIGHT RHD MODEL S914418A2103 SR24-20A LI-34...
  • Page 36 INTERIOR LIGHT SYSTEM Lighting System SR24-20B LI-35...
  • Page 37 INTERIOR LIGHT SYSTEM Lighting System B: INSPECTION S914418A10 1. DOOR SWITCH S914418A1001 Check continuity between terminals. Specified condi- Switch position Tester connection tion When door is Continuity open. 1 - ground When door is No continuity closed. 2. REAR GATE LATCH SWITCH S914418A1002 Check continuity between terminals.
  • Page 38 INTERIOR LIGHT SYSTEM Lighting System MEMO: LI-37...

  • Page 39: Headlight Beam Leveler System

    HEADLIGHT BEAM LEVELER SYSTEM Lighting System 9. Headlight Beam Leveler System S914493 A: SCHEMATIC S914493A21 1. HEADLIGHT BEAM LEVELER S914493A2101 SG83-20 LI-38...
  • Page 40 HEADLIGHT BEAM LEVELER SYSTEM Lighting System B: INSPECTION S914493A10 1. HEADLIGHT BEAM LEVELER ACTUATOR S914493A1001 1) Turn on the headlights. 2) Confirm the headlight beam level is lowered by changing the switch position to 0 - 1 - 2 - 3 - 4 - 5. 2.

  • Page 41: Combination Switch (Light)

    COMBINATION SWITCH (LIGHT) Lighting System 10. Combination Switch (Light) C: INSPECTION S914411A10 S914411 A: REMOVAL S914411A18 1) Remove instrument panel lower cover. <Ref. to EI-31 REMOVAL, Instrument Panel Assembly.> 2) Remove screws which secure upper column cover to lower column cover. S6M0042 3) Disconnect connector from combination switch.

  • Page 42: Turn Signal Switch

    COMBINATION SWITCH (LIGHT) Lighting System RHD model: Specified condi- Switch position Tester connection tion Passing 1 - 2 - 9 Continuity Low beam 9 - 10 Continuity High beam 2 - 9 Continuity 3. TURN SIGNAL SWITCH S914411A1003 LHD model: Specified condi- Switch position Tester connection...

  • Page 43: Headlight Assembly

    HEADLIGHT ASSEMBLY Lighting System 11. Headlight Assembly B: INSTALLATION S914409A11 S914409 Install in the reverse order of removal. A: REMOVAL S914409A18 1) Remove duct (A) (when right side headlight is C: ADJUSTMENT S914409A01 removed). 1. HEADLIGHT AIMING S914409A0101 CAUTION: Turn off the light before adjusting headlight aiming.
  • Page 44 HEADLIGHT ASSEMBLY Lighting System S6M0535A This illustration is for LHD model. The pattern for RHD model is symmetrically opposite. H mm (in) W mm (in) h mm (in) at 3 m (10 ft) Non-turbo model Turbo model 1,090 (42.91) 710 (27.95) 697 (27.44) 30 (1.18) LI-43...

  • Page 45: Headlight Bulb

    HEADLIGHT BULB Lighting System 12. Headlight Bulb B: INSTALLATION S914410A11 S914410 Install in the reverse order of removal. A: REMOVAL S914410A18 CAUTION: ¼ Because the tungsten halogen bulb operates at a high temperature, dirt and oil on the bulb surface reduces the bulb’s service life. Hold the flange portion when replacing the bulb.

  • Page 46: Front Turn Signal Light Assembly

    FRONT TURN SIGNAL LIGHT ASSEMBLY Lighting System 13. Front Turn Signal Light Assembly S914408 A: REMOVAL S914408A18 1) Remove screw and disconnect connector, and then detach front turn signal light assembly. S6M0538 B: INSTALLATION S914408A11 Install in the reverse order of removal. LI-45...

  • Page 47: Front Turn Signal Light Bulb

    FRONT TURN SIGNAL LIGHT BULB Lighting System 14. Front Turn Signal Light Bulb S914412 A: REMOVAL S914412A18 1) Remove front turn signal light assembly. <Ref. to LI-45, REMOVAL, Front Turn Signal Light Assembly.> 2) Turn the socket and remove the bulb. S6M0539 B: INSTALLATION S914412A11...

  • Page 48: Parking Light Bulb

    PARKING LIGHT BULB Lighting System 15. Parking Light Bulb S914419 A: REMOVAL S914419A18 1) Remove headlight assembly. <Ref. to LI-42 REMOVAL, Headlight Assembly.> 2) Turn the socket and remove the bulb. S6M0540 B: INSTALLATION S914419A11 Install in the reverse order of removal. LI-47...

  • Page 49: Front Fog Light Assembly

    FRONT FOG LIGHT ASSEMBLY Lighting System 16. Front Fog Light Assembly S914427 A: REMOVAL S914427A18 1) Remove the two screws, then draw out the front fog light from front bumper. S6M0085 2) Disconnect the connector. B: INSTALLATION S914427A11 Install in the reverse order of removal. LI-48...

  • Page 50: Front Fog Light Bulb

    FRONT FOG LIGHT BULB Lighting System 17. Front Fog Light Bulb S914428 A: REMOVAL S914428A18 1) Remove front fog light assembly. <Ref. to LI-48 REMOVAL, Front Fog Light Assembly.> 2) Remove front fog light bulb (A). S6M0541A B: INSTALLATION S914428A11 Install in the reverse order of removal.

  • Page 51: Rear Combination Light Assembly

    REAR COMBINATION LIGHT ASSEMBLY Lighting System 18. Rear Combination Light Assembly S914426 A: REMOVAL S914426A18 1) Remove rear quarter upper and lower trim. <Ref. to EI-39 REMOVAL, Rear Quarter Trim.> 2) Remove nuts and disconnect connector. S6M0045 3) Attach adhesive cloth tape to body area around rear combination light.

  • Page 52: Rear Finisher Light Assembly

    REAR FINISHER LIGHT ASSEMBLY Lighting System 19. Rear Finisher Light Assembly S914429 A: REMOVAL S914429A18 1) Remove rear gate trim access hole cover. 2) Remove the four nuts. S6M0427 3) Detach rear finisher light while disconnecting connector. 4) Install in the reverse order of removal. B: INSTALLATION S914429A11 Install in the reverse order of removal.

  • Page 53: Brake/Tail Light Bulb

    BRAKE/TAIL LIGHT BULB Lighting System 20. Brake/Tail Light Bulb S914430 A: REMOVAL S914430A18 1) Remove rear combination light cover. 2) Turn the socket and remove the bulb. S6M0542 B: INSTALLATION S914430A11 Install in the reverse order of removal. LI-52...

  • Page 54: Back-Up Light Bulb

    BACK-UP LIGHT BULB Lighting System 21. Back-up Light Bulb S914424 A: REMOVAL S914424A18 1) Remove rear gate trim access hole cover. 2) Turn the socket and remove the bulb. S6M0543 B: INSTALLATION S914424A11 Install in the reverse order of removal. LI-53...

  • Page 55: Rear Turn Signal Light Bulb

    REAR TURN SIGNAL LIGHT BULB Lighting System 22. Rear Turn Signal Light Bulb S914421 A: REMOVAL S914421A18 1) Remove rear combination light cover. 2) Turn the socket and remove the bulb. S6M0544 B: INSTALLATION S914421A11 Install in the reverse order of removal. LI-54...

  • Page 56: Rear Fog Light Assembly

    REAR FOG LIGHT ASSEMBLY Lighting System 23. Rear Fog Light Assembly S914422 A: REMOVAL S914422A18 1) Disconnect connector from rear fog light. 2) Remove nuts and then detach rear fog light. NOTE: Take out rear fog light by pulling out it from behind the bumper.

  • Page 57: Rear Fog Light Bulb

    REAR FOG LIGHT BULB Lighting System 24. Rear Fog Light Bulb S914423 A: REMOVAL S914423A18 1) Remove screw (A) and rear fog light lens (B). S6M0545A 2) Remove the bulb. B: INSTALLATION S914423A11 Install in the reverse order of removal. LI-56...

  • Page 58: License Plate Light

    LICENSE PLATE LIGHT Lighting System 25. License Plate Light S914420 A: REMOVAL S914420A18 1) Remove license plate light mounting screw (A) and then remove the lens (B) S6M0546A 2) Remove the bulb. B: INSTALLATION S914420A11 Install in the reverse order of removal. LI-57...

  • Page 59: High-Mounted Stop Light

    HIGH-MOUNTED STOP LIGHT Lighting System 26. High-mounted Stop Light S914425 A: REMOVAL S914425A18 1) Remove cap (a) by prying on the edge with a screwdriver. 2) Remove screws (b) and then detach cover (c). 3) Remove screws (d) and then detach high- mounted stop light while disconnecting connector.

  • Page 60: Side Turn Signal Light

    SIDE TURN SIGNAL LIGHT Lighting System 27. Side Turn Signal Light S914407 A: REMOVAL S914407A18 1) Pull out the light from body while pushing it in direction of vehicle front. 2) Disconnect harness connector and remove the light. B6M1543 B: INSTALLATION S914407A11 Install in the reverse order of removal.

  • Page 61: Spot Light

    SPOT LIGHT Lighting System 28. Spot Light S914398 A: REMOVAL S914398A18 1) Remove spot light lens (A). S6M0547A 2) Remove sunroof switch. <Ref. to SR-12, REMOVAL, Sunroof Switch.> 3) Remove spot light mounting screw (B). S6M0548A 4) Disconnect harness connectors and remove spot light.

  • Page 62: Room Light

    ROOM LIGHT Lighting System 29. Room Light S914397 A: REMOVAL S914397A18 1) Remove lens (A) and room light mounting screws (B). B6M1479A 2) Disconnect harness connectors and remove the light. B: INSTALLATION S914397A11 Install in the reverse order of removal. C: INSPECTION S914397A10 B6M1489A...

  • Page 63: Luggage Room Light

    LUGGAGE ROOM LIGHT Lighting System 30. Luggage Room Light S914399 A: REMOVAL S914399A18 1) Remove lens (A) and luggage room light mounting screws (B). B6M1480A 2) Disconnect harness connectors and remove luggage room light. B: INSTALLATION S914399A11 Install in the reverse order of removal. C: INSPECTION S914399A10 B6M1490A...

  • Page 64: Glove Box Light

    GLOVE BOX LIGHT Lighting System 31. Glove Box Light S914396 A: REMOVAL S914396A18 1) Remove glove box. <Ref. to EI-28 REMOVAL, Glove Box.> 2) Disconnect harness connector. 3) Remove glove box light. S6M0549 B: INSTALLATION S914396A11 Install in the reverse order of removal. LI-63...
  • Page 65 GLOVE BOX LIGHT Lighting System MEMO: LI-64...

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