Subaru 2001 FORESTER Service Manual
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Subaru 2001 FORESTER Service Manual

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2001 FORESTER SERVICE MANUAL
GENERAL INFORMATION
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
G8050GE1

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  • 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 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 3 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 4 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 5 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 6: 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 7 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION G8050GE6...
  • Page 8 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 9 FOREWORD Page Foreword .....................2...
  • Page 10 FOREWORD Foreword 1. Foreword SA01674 A: FOREWORD SA01674G21 These manuals are used when performing maintenance, repair, or diagnosis of the Subaru Forester. Applied model: SF***** from 2001MY. The additional manuals below are also available: AUTOMATIC TRANSMISSION SERVICE MANUAL (Pub. No. G0853ZE) The manuals contain the latest information at the time of publication.

  • Page 11: How To Use This Manuals

    HOW TO USE THIS MANUALS Page How to Use This Manuals................2...

  • Page 12: Table Of Contents

    HOW TO USE THIS MANUALS How to Use This Manuals 1. How to Use This Manuals SA02675 A: HOW TO USE THIS MANUALS SA02675F69 1. STRUCTURE SA02675F6901 Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.

  • Page 13: Specifications

    SPECIFICATIONS Page Forester .......................2...
  • Page 14 FORESTER Specifications 1. Forester SA08758 A: DIMENSIONS SA08758G28 Model 2.0 L Non-TURBO 2.0 L TURBO Overall length mm (in) 4,460 (175.6), 4,530 (178.3)*1 Overall width mm (in) 1,735 (68.3), 1,765 (69.5)*2 Overall height (at CW) mm (in) 1,595 (62.8) 1,585 (62.4) Compartment Length mm (in)
  • Page 15 FORESTER Specifications D: TRANSMISSION SA08758G31 Model 2.0 L Non-TURBO 2.0 L TURBO Transmission type 5MT*1 4AT*2 5MT*1 4AT*2 Clutch type DSPD DSPD Gear ratio 3.454 2.785 3.454 2.785 2.062 1.545 1.947 1.545 1.448 1.000 1.366 1.000 1.088 0.694 0.972 0.694 0.871 —...
  • Page 16 FORESTER Specifications G: BRAKE SA08758G34 Model Australia spec. vehicles and 2000 Others TURBO Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Disc brake Drum brake Parking brake Mechanical on rear brakes H: TIRE SA08758G35 15 ×...
  • Page 17 FORESTER Specifications J: WEIGHT SA08758G37 1. EXCEPT AUSTRALIA SPEC. VEHICLE SA08758G3706 Model 2.0 L Non-TURBO Curb weight (CW) Front kg (lb) 730 (1,610) 745 (1,643) 745 (1,643) 760 (1,676) Rear kg (lb) 615 (1,356) 615 (1,356) 620 (1,367) 620 (1,367) Total kg (lb) 1,345 (2,966)
  • Page 18 FORESTER Specifications 2. AUSTRALIA SPEC. VEHICLE SA08758G3704 Model 2.0 L Non-TURBO 2.0 L TURBO Unladen mass (UM) Front kg (lb) 740 (1,632) 755 (1,665) 810 (1,786) 835 (1,841) Rear kg (lb) 625 (1,378) 625 (1,378) 630 (1,389) 625 (1,378) Total kg (lb) 1,365 (3,010) 1,380 (3,043)
  • Page 19 PRECAUTION Page Precaution ....................2...

  • Page 20: Components

    PRECAUTION Precaution 1. Precaution 7. AIRBAG MODULE SA04677F5907 SA04677 Adhere to the following when handing and storing A: PRECAUTION SA04677F59 the airbag module to prevent bodily injury from Please clearly understand and adhere to the fol- unexpected deployment: ¼ Do not hold harnesses or connectors to carry lowing general precautions.
  • Page 21 NOTE Page Note ......................2...
  • Page 22 ECM from rush current. 4. SERVICE PARTS SA03676A1504 Use authentic service parts for maximum perfor- mance maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts not specified by a genuine dealer. NT-2...
  • Page 23 NOTE Note 5. LIFTS AND JACKS SA03676A1505 When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the vehicle is balanced before raising it.
  • Page 24 NOTE Note S1M0138A S1M0139A NT-4...
  • Page 25 S1M0141A 9. GENERAL SCAN TOOL SA03676A1509 Using general scan tools will greatly improve effi- ciency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, and other parts. GI0103 NT-5...
  • Page 26 NOTE Note MEMO: NT-6...
  • Page 27 IDENTIFICATION Page Identification ....................2...
  • Page 28 IDENTIFICATION Identification 1. Identification SA06679 A: IDENTIFICATION SA06679F70 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS SA06679F7001 The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification S1M0148A GI0007A GI0009A ID-2...
  • Page 29 IDENTIFICATION Identification S1M0149A GI0008A GI0011A ID-3...
  • Page 30 IDENTIFICATION Identification 2. MEANING OF V.I.N. SA06679F7002 The meaning of the VIN is as follows: ¼ Europe, Australia and General (Except GCC) ]JF1SF5LJ31G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made JF2: MPV, FHI made Car line...

  • Page 31: Specifications

    IDENTIFICATION Identification 3. MODEL NUMBER PLATE SA06679F7003 The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. SF9CL7R Digits Code...
  • Page 32 IDENTIFICATION Identification ¼ Transmission TZ1A3ZS3AA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: MT 1A: New AT Series 3: AT 5: MT Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center tions differential single range...
  • Page 33 RECOMMENDED MATERIALS Page Recommended Materials ................2...
  • Page 34 RECOMMENDED MATERIALS Recommended Materials 1. Recommended Materials SA05678 A: RECOMMENDED MATERIALS SA05678G22 1. GENERAL SA05678G2201 To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or that of equivalent quality. 2. FUEL SA05678G2202 Always use a gasoline of the same or higher octane value than specified in the owner’s manual.
  • Page 35 RECOMMENDED MATERIALS Recommended Materials 3. LUBRICANTS SA05678G2203 Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the cor- rect SAE viscosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. Engine oil SJ Grade “Energy conserving”...
  • Page 36 FMVSS No. 116 DOT4 Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 5. COOLANT SA05678G2205 Use genuine coolant to protect the engine. Coolant Recommended Item number Alternative Coolant SUBARU coolant 000016218 None Water for dilution Distilled water — Tap water RM-4...
  • Page 37 *: It is recommended that distilled water be used. 6. REFRIGERANT SA05678G2206 Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refriger- ants. Also, do not use any air compressor oil except for ZXL200PG and DENSO OIL 9. Air conditioner...
  • Page 38 RECOMMENDED MATERIALS Recommended Materials 8. ADHESIVES SA05678G2210 Use the adhesives shown in the table below, or equivalent. Adhesive Application point Recommended Item number Alternative Adhesive Windshield and body Essex Chemical Crop’s Ure- — Sunstar 580 thane E Weatherstrip, rubber Cemedine 5430L —...

  • Page 39: Inspection

    PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
  • Page 40 PRE-DELIVERY INSPECTION Pre-delivery Inspection 1. Pre-delivery Inspection SA09719 A: GENERAL SA09719G23 The purposes of the pre-delivery inspection (PDI) are as follows. ¼ Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. ¼...
  • Page 41 PRE-DELIVERY INSPECTION Pre-delivery Inspection B: PDI PROCEDURE SA09719G50 Follow the procedures shown in the table below. Static Checks Just After Vehicle Receipt Step Check point 1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents.
  • Page 42 PRE-DELIVERY INSPECTION Pre-delivery Inspection Checks with the Engine Running Step Check point 1. Read memory and test mode connectors (1) Read memory and test mode connectors 2. Starting condition (1) Start the engine and check that the engine starts smoothly. 3.
  • Page 43 PRE-DELIVERY INSPECTION Pre-delivery Inspection 1. APPEARANCE CHECK 4. CHECK THE DOOR OPERATIONS, SA09719G5001 LOCK/UNLOCK AND OPEN/CLOSE, AS ¼ If the vehicle is covered with protective coating, FOLLOWS. visually check the vehicle body for damage and SA09719G5003 dents. Using the key, lock and unlock the door several ¼...
  • Page 44 PRE-DELIVERY INSPECTION Pre-delivery Inspection 6. OPERATION CHECK OF REAR GATE 9. ACCESSORY CHECK SA09719G5008 LOCK RELEASE LEVER SA09719G5006 Check that the following accessories are provided ¼ Operate the rear gate lock release lever and in the luggage compartment or cargo area. ¼...
  • Page 45 PRE-DELIVERY INSPECTION Pre-delivery Inspection 11. CONNECTION OF AIR CONDITIONER 14. ENGINE OIL SA09719G5014 HARNESS SA09719G5011 Check the engine oil amount. If the amount is insufficient, check that no leaks are found. Then, A vehicle just delivered has its air conditioner har- add the necessary amount of the specified engine ness disconnected to protect the air conditioner oil.
  • Page 46 PRE-DELIVERY INSPECTION Pre-delivery Inspection 17. COOLANT 21. KEYLESS ENTRY SYSTEM SA09719G5017 SA09719G5021 Check the coolant amount on the reservoir. If the Check the keyless entry system operations as fol- amount is insufficient, check that no leaks are lows. ¼ Remove the key from the ignition switch and found.
  • Page 47 PRE-DELIVERY INSPECTION Pre-delivery Inspection 25. READ MEMORY AND TEST MODE 30. RADIO SA09719G5033 CONNECTORS Check the radio for full functionality and normal SA09719G5050 noise level. Also check the CD unit operations. Turn the ignition switch to ON and check that the check-engine light starts blinking.
  • Page 48 PRE-DELIVERY INSPECTION Pre-delivery Inspection 38. AT SHIFT CONTROL 43. POWER STEERING FLUID LEVEL SA09719G5041 SA09719G5046 Set the AT select lever to each gear position while checking that the demanded gear position is cor- 1) Check power steering fluid for deterioration or rectly attained.
  • Page 49 PRE-DELIVERY INSPECTION Pre-delivery Inspection 45. WATER LEAK TEST SA09719G5048 Spray the vehicle with water and check that no water enters the passenger compartment. ¼ Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry. ¼...
  • Page 50 PRE-DELIVERY INSPECTION Pre-delivery Inspection MEMO: PI-12...

  • Page 51: Maintenance

    PERIODIC MAINTENANCE SERVICES Page General Description..................2 Schedule......................3 Engine Oil....................6 Engine Oil Filter...................8 Spark Plugs ....................9 Drive Belt(s)....................10 Camshaft Drive Belt ..................12 Valve Clearance ..................14 Fuel Line....................15 Fuel Filter ....................16 Air Cleaner Element ..................17 Cooling System ..................18 Coolant ......................19 Idle Mixture....................21 Clutch System ...................22 Hill-holder System ..................24 Transmission Oil..................25...

  • Page 52: General Description

    GENERAL DESCRIPTION Periodic Maintenance Services 1. General Description SA07001 A: GENERAL SA07001G23 Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...
  • Page 53 SCHEDULE Periodic Maintenance Services 2. Schedule SA07682 A: MAINTENANCE SCHEDULE 1 SA07682G24 1. MAINTENANCE SCHEDULE 1 – (1) SA07682G2401 For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by refer- ring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.
  • Page 54 SCHEDULE Periodic Maintenance Services Maintenance Interval [Number of months or km (miles), whichever occurs first] Months Remarks × 1,000 km × 1,000 miles Wheel bearing Axle boots & joints Steering system (Power steering) Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: (1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
  • Page 55 SCHEDULE Periodic Maintenance Services B: MAINTENANCE SCHEDULE 2 SA07682G25 Item Every Repeat short Repeat Extremely Salt or other High humidity Repeat tow- distance drive rough/muddy cold weather corrosive or mountain ing trailer road drive area used or area coastal area Engine oil Replace more Replace more...

  • Page 56: Engine Oil

    1) Drain engine oil by loosening engine oil drain tion and SAE viscosity No. designated by plug. SUBARU. ¼ If vehicle is used in desert areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: API classification: SJ or SH SAE Viscosity No.: 30, 40, 10W-50, 20W-40,...
  • Page 57 ENGINE OIL Periodic Maintenance Services B: INSPECTION SA07077A10 1) Park vehicle on a level surface. 2) Remove oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation.

  • Page 58: Engine Oil Filter

    ENGINE OIL FILTER Periodic Maintenance Services 4. Engine Oil Filter SA07585 A: REPLACEMENT SA07585A20 1) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH GI0012A 2) Get a new oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install oil filter by turning it by hand, being care- ful not to damage seal rubber.

  • Page 59: Spark Plugs

    SPARK PLUGS Periodic Maintenance Services 5. Spark Plugs tighten further 1/4 to 1/2 turns. SA07683 2. TURBO MODEL SA07683A2004 A: REPLACEMENT SA07683A20 NOTE: 1. NON-TURBO MODEL For spark plug replacement procedure details, SA07683A2003 refer to IG section. <Ref. to IG(DOHC TURBO)-4, NOTE: Spark Plug.>...
  • Page 60 DRIVE BELT(S) Periodic Maintenance Services 6. Drive Belt(s) B: REPLACEMENT SA07684A20 SA07684 NOTE: A: INSPECTION SA07684A10 Wipe off any oil or water on the belt and pulley. 1) Replace belts, if cracks, fraying or wear is 1) Loosen the lock bolt (A). found.
  • Page 61 DRIVE BELT(S) Periodic Maintenance Services Tightening torque: Lock bolt, through bolt: 25 N·m (2.5 kgf-m, 18 ft-lb) Slider bolt: 8 N·m (0.8 kgf-m, 5.8 ft-lb) GI0021A PM-11...
  • Page 62 CAMSHAFT DRIVE BELT Periodic Maintenance Services 7. Camshaft Drive Belt 2. DOHC MODEL SA07685A2002 SA07685 NOTE: A: REPLACEMENT SA07685A20 For camshaft drive belt replacement procedure details, refer to ME(DOHC) section. <Ref. to 1. SOHC MODEL SA07685A2001 ME(SOHC)-46, Timing Belt Assembly.> NOTE: 1) Remove radiator fan and air conditioning fan.
  • Page 63 CAMSHAFT DRIVE BELT Periodic Maintenance Services B: INSTALLATION C: INSPECTION SA07685A11 SA07685A10 1. SOHC MODEL 1. SOHC MODEL SA07685A1101 SA07685A1001 Install in the reverse order of removal. <Ref. to 1) Remove left and right timing belt covers. ME(SOHC)-46, Timing Belt Assembly.> 2) While cranking engine at least four rotations, check timing belt back surface for cracks or dam- 2.

  • Page 64: Valve Clearance

    VALVE CLEARANCE Periodic Maintenance Services 8. Valve Clearance SA07083 A: INSPECTION SA07083A10 For the inspection procedures of the valve clear- ance: <Ref. to ME(SOHC)-29, Valve Clearance.> or <Ref. to ME(DOHC TURBO)-28, Valve Clear- ance.> PM-14...

  • Page 65: Fuel Line

    FUEL LINE Periodic Maintenance Services 9. Fuel Line SA07686 A: INSPECTION SA07686A10 The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. <Ref. to FU(SOHC)-69, Fuel Delivery, Return and Evaporation Lines.>...

  • Page 66: Fuel Filter

    FUEL FILTER Periodic Maintenance Services 10. Fuel Filter SA07027 A: REPLACEMENT SA07027A20 For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU(SOHC)-66, Fuel Filter.> or <Ref. to FU(SOHCw/oOBD)-54 Fuel Filter.> or <Ref. to FU(DOHC TURBO)-64, Fuel Filter.> PM-16...

  • Page 67: Air Cleaner Element

    AIR CLEANER ELEMENT Periodic Maintenance Services 11. Air Cleaner Element 2. TURBO MODEL SA07687A2002 SA07687 A: REPLACEMENT SA07687A20 NOTE: Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a special inflammable slow-evaporating viscous liq- uid.

  • Page 68: Cooling System

    COOLING SYSTEM Periodic Maintenance Services 12. Cooling System Raise the pressure until the needle of gauge stops SA07688 and see if the pressure can be retained for five to A: INSPECTION six seconds. The radiator cap is normal if a pres- SA07688A10 sure above the service limit value has been main- 1) Check radiator for leakage, filling it with coolant...
  • Page 69 (6.7 US qt, 5.5 Imp qt) NOTE: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion. (2) Securely install radiator cap.
  • Page 70 To adjust the concentration of the coolant accord- The concentration and safe operating temperature ing to temperature, find the proper fluid concentra- of the SUBARU coolant is shown in the diagram. tion in the above diagram and replace the neces- Measuring the temperature and specific gravity of sary amount of coolant with an undiluted solution the coolant will provide this information.

  • Page 71: Idle Mixture

    IDLE MIXTURE Periodic Maintenance Services 14. Idle Mixture SA07734 A: INSPECTION AND ADJUSTMENT SA07734G26 1. IDLE MIXTURE SA07734G2601 Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at “Neutral” for MT, or “N” or “P”...

  • Page 72: Clutch System

    CLUTCH SYSTEM Periodic Maintenance Services 15. Clutch System Standard: SA07690 80 mm (3.15 in) or more A: INSPECTION AND ADJUSTMENT 3) Pedal height SA07690G26 Check that the clutch pedal pad surface is level with or higher than brake pedal pad surface. 1.
  • Page 73 CLUTCH SYSTEM Periodic Maintenance Services NOTE: ¼ Avoid mixing different brakes of brake fluid to prevent degradation of the fluid. ¼ Be careful not to allow dirt or dust to get into the reservoir tank. GI0040A PM-23...

  • Page 74: Hill-Holder System

    HILL-HOLDER SYSTEM Periodic Maintenance Services 16. Hill-holder System SA07735 A: INSPECTION AND ADJUSTMENT SA07735G26 1) Confirm stopping and starting performance by activating hill-holder on an uphill road of 3° or higher inclination. (1) When vehicle does not stop; Tighten adjusting nut of PHV cable. (2) When vehicle does not start properly;...

  • Page 75: Transmission Oil

    TRANSMISSION OIL Periodic Maintenance Services 17. Transmission Oil SA07691 A: REPLACEMENT SA07691A20 1. MANUAL TRANSMISSION SA07691A2001 1) Drain gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. GI0041 2) Reinstall drain plug after draining gear oil and tighten it to the specified torque.
  • Page 76 Periodic Maintenance Services 18. ATF 2. ATF FILTER SA07692A2002 SA07692 NOTE: A: REPLACEMENT SA07692A20 ATF filter is maintenance free part. ATF filter needs 1. AUTOMATIC TRANSMISSION FLUID replacement, when it has physically damaged or ATF leaked. SA07692A2001 For the replacement procedures of the ATF filter: 1) Drain ATF (Automatic Transmission Fluid) by <Ref.
  • Page 77 FRONT & REAR DIFFERENTIAL OIL Periodic Maintenance Services 19. Front & Rear Differential Oil 3) Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge. SA07693 Differential gear oil capacity: A: REPLACEMENT SA07693A20 1.1 —...
  • Page 78 FRONT & REAR DIFFERENTIAL OIL Periodic Maintenance Services 5) Install filler plug onto rear differential gear case firmly. NOTE: ¼ Apply fluid packing to filler plug before installa- tion in T-type. ¼ VA-type uses a new aluminum gasket. Fluid packing: Three Bond 1105 Tightening torque: T-type:...
  • Page 79 BRAKE LINE Periodic Maintenance Services 20. Brake Line B: CHECKING SA07694G27 SA07694 1. SERVICE BRAKE A: INSPECTION SA07694G2701 SA07694A10 1) Check the free play of brake pedal with a force 1. BRAKE LINE SA07694A1001 of less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion and/or Brake pedal free play: traces of fluid leakage on brake hoses or pipe...
  • Page 80 BRAKE LINE Periodic Maintenance Services 3) Check the pedal stroke. 4) Check valve is built into vacuum hose. Discon- nect vacuum hose to inspect function of check While the engine is idling, depress the brake pedal valve. with a 490 N (50 kgf, 110 lb) load and measure the Blow air into vacuum hose from its brake booster distance between the brake pedal and steering side end: Air must flow out of engine side end of...

  • Page 81: Brake Fluid

    BRAKE FLUID Periodic Maintenance Services 21. Brake Fluid NOTE: SA07162 ¼ Cover bleeder with waste cloth, when loosening A: REPLACEMENT it, to prevent brake fluid from being splashed over SA07162A20 surrounding parts. 1) Either jack up vehicle and place a safety stand ¼...

  • Page 82: Disc Brake Pads And Discs

    DISC BRAKE PADS AND DISCS Periodic Maintenance Services 22. Disc Brake Pads and Discs NOTE: When replacing a pad, always replace the pads for SA07695 both the left and right wheels at the same time. A: INSPECTION Also replace pad clips if they are twisted or worn. SA07695A10 1.
  • Page 83 BRAKE LININGS AND DRUMS Periodic Maintenance Services 23. Brake Linings and Drums If deformation or wear of back plate, shoe, etc. is noticeable, replace the affected parts. SA07696 A: INSPECTION SA07696A10 1. REAR DRUM BRAKE SA07696A1001 1) Remove brake drum, and check that there is no fluid leakage from wheel cylinder.
  • Page 84 BRAKE LININGS AND DRUMS Periodic Maintenance Services 2) Check brake drum for wear, dents or other B: ADJUSTMENT SA07696A01 damage. If the inside surface of brake drum is 1. REAR DRUM BRAKE streaked, correct the surface with emery cloth SA07696A0101 (#200 or more).
  • Page 85 SUSPENSION Periodic Maintenance Services 24. Suspension NOTE: SA07697 When transverse link ball joint has been removed A: INSPECTION or replaced, check toe-in of front wheel. If front SA07697A10 wheel toe-in is not at specified value, adjust toe-in. 1. SUSPENSION BALL JOINT SA07697A1001 <Ref.
  • Page 86 SUSPENSION Periodic Maintenance Services 4. WHEEL ALIGNMENT OF FRONT 8. DAMAGE TO SUSPENSION PARTS SUSPENSION SA07697A1008 SA07697A1004 1) Check the following parts and the fastening por- 1) Check alignment of front suspension to ensure tion of the vehicle body for deformation or exces- that following items conform to standard values.

  • Page 87: Wheel Bearing

    WHEEL BEARING Periodic Maintenance Services 25. Wheel Bearing 6) While supporting rear drive shaft horizontally SA07698 with one hand, turn hub COMPL with the other to A: INSPECTION check for noise or binding. SA07698A10 If hub COMPL is noisy or binds, disassemble rear 1.

  • Page 88: Axle Boots & Joints

    AXLE BOOTS & JOINTS Periodic Maintenance Services 26. Axle Boots & Joints SA07699 A: INSPECTION SA07699A10 1. FRONT AND REAR AXLE BOOTS SA07699A1001 Inspect front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones.
  • Page 89 STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services 27. Steering System (Power 2. STEERING SHAFT JOINT SA07701A1002 Steering) 1) When steering wheel free play is excessive, SA07701 disconnect universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the SA07701A10 point of the crossing direction).
  • Page 90 STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services 3) With vehicle on a level surface, quickly turn 3) Check lock nut on the tie-rod end for tightness. steering wheel to the left and right. If it is loose, retighten it to the specified torque. While steering wheel is being rotated, check the Tightening torque: gear backlash.

  • Page 91: Diagnosis

    STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services Recommended fluid: 9. GEARBOX BOOTS SA07701A1009 Dexron IIE or III Inspect both sides of gearbox boots as follows, and Fluid capacity: correct the defects if necessary. (0.7 US qt, 0.6 Imp qt) 1) (A) and (B) positions of gearbox boot are fitted correspondingly in (A) and (B) grooves of gearbox 6.

  • Page 92: Supplemental Restraint System

    SUPPLEMENTAL RESTRAINT SYSTEM Periodic Maintenance Services 28. Supplemental Restraint System SA07702 A: INSPECTION SA07702A10 Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnos- tic Procedure.> 1) Ensure that airbag connectors are connected. If not, properly connect (also double lock the connector). When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light turns on to identify the fault.

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Forester 2.0 l turbo 2001

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