Subaru FORESTER 2001 Service Manual
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Subaru FORESTER 2001 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 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

    EXTERIOR BODY PANELS Page General Description..................2 Front Hood ....................9 Fender Panel.....................10 Front Door Panel ..................11 Front Sealing Cover ..................13 Rear Door Panel ..................14 Rear Sealing Cover...................16 Rear Gate Panel ..................17...

  • Page 3: General Description

    GENERAL DESCRIPTION Exterior Body Panels 1. General Description S913001 A: SPECIFICATIONS S913001E49 S5M0380A EB-2...
  • Page 4 GENERAL DESCRIPTION Exterior Body Panels B: COMPONENT S913001A05 1. FRONT HOOD S913001A0501 S5M0442A (1) Front hood (5) Front hood stay Tightening torque: N·m (kg-m, ft-lb) (2) Striker 24.5 (2.5, 18.1) (3) Hinge 33 (3.4, 25) (4) Seal EB-3...

  • Page 5: Front Door Panel

    GENERAL DESCRIPTION Exterior Body Panels 2. FRONT DOOR PANEL S913001A0502 S5M0506A (1) Gusset (7) Sealing cover Tightening torque: N·m (kgf-m, ft-lb) (2) Weatherstrip (8) Lower hinge 7.35 (0.75, 5.4) (3) Stabilizer (Outer) (9) Upper hinge 13 (1.3, 9.4) (4) Stabilizer (Inner) 25 (2.5, 18) (5) Door panel 30 (3.1, 22)
  • Page 6 GENERAL DESCRIPTION Exterior Body Panels 3. REAR DOOR PANEL S913001A0503 S5M0507A (1) Weatherstrip (7) Checker Tightening torque: N·m (kgf-m, ft-lb) (2) Stabilizer (Outer) (8) Lower hinge 7.35 (0.75, 5.4) (3) Stabilizer (Inner) (9) Upper hinge 25 (2.5, 18) (4) Door panel 30 (3.1, 18) (5) Plate 32 (3.3, 24)
  • Page 7 GENERAL DESCRIPTION Exterior Body Panels 4. REAR GATE PANEL S913001A0505 S5M0443B (1) Gas stay (5) Buffer cover Tightening torque: N·m (kg-m, ft-lb) (2) Hinge (6) Buffer (Back door) 7.5 (0.76, 5.5) (3) Rear gate 14 (1.4, 10.1) (4) Stopper 25 (2.5, 18.1) EB-6...
  • Page 8 GENERAL DESCRIPTION Exterior Body Panels C: CAUTION S913001A03 ¼ Exterior body panels are heavy. Do not drop and damage panels. During removal installation, do not damage the panel painting sur- face. ¼ While removing mounting bolts, using assis- tance devices such as a support jack will help sup- port the panel.
  • Page 9 GENERAL DESCRIPTION Exterior Body Panels D: PREPARATION TOOL S913001A17 1. SPECIAL TOOLS S913001A1701 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hing. B5M1117 2. GENERAL TOOL S913001A1702 TOOL NAME REMARKS Support Jack Used for supporting door panel. EB-8...

  • Page 10: Front Hood

    FRONT HOOD Exterior Body Panels 2. Front Hood S913367 A: REMOVAL S913367A18 1) Open front hood to remove washer nozzles. 2) Remove bolts to detach hood from hinges. G5M0137 B: INSTALLATION S913367A11 1) Install in the reverse order of removal. 2) Adjust clearance between hood and fender.

  • Page 11: Fender Panel

    FENDER PANEL Exterior Body Panels 3. Fender Panel S913368 A: REMOVAL S913368A18 1) Disconnect ground (−) cable from battery. 2) Remove side protectors and fender protectors. <Ref. to EI-22, REMOVAL, Protector.> 3) Remove mud guard. <Ref. to EI-21 REMOVAL, Mud Guard.> 4) Remove front bumper face.

  • Page 12: Front Door Panel

    FRONT DOOR PANEL Exterior Body Panels 4. Front Door Panel 10) Remove checker bolts. S913366 A: REMOVAL S913366A18 1) Disconnect (−) cable from battery. 2) Remove front door trim. <Ref. to EI-26 REMOVAL, Front Door Trim.> 3) Remove outer mirror assembly. <Ref. to GW-49 REMOVAL, Outer Mirror Assembly.>...
  • Page 13 FRONT DOOR PANEL Exterior Body Panels C: ADJUSTMENT S913366A01 1) Using special tool, loosen body-side bolts of upper and lower hinges to align the position of front door panel longitudinally and vertically. ST 925610000 DOOR HINGE WRENCH B5M0933A 2) Loosen door-side bolts of upper and lower hinges to align the position of front door panel ver- tically and laterally at the front end.

  • Page 14: Front Sealing Cover

    FRONT SEALING COVER Exterior Body Panels 5. Front Sealing Cover S913564 A: REMOVAL S913564A18 1) Remove front door trim. <Ref. to EI-26 REMOVAl, Front Door Trim.> 2) Remove front speaker. <Ref. EI-12 REMOVAL, Front Speaker.> 3) Using a spatula, remove sealer. CAUTION: ¼...

  • Page 15: Rear Door Panel

    REAR DOOR PANEL Exterior Body Panels 6. Rear Door Panel 9) Remove checker bolts. S913364 A: REMOVAL S913364A18 1) Disconnect (−) cable from battery. 2) Remove rear door trim. <Ref. to EI-27 REMOVAL, Rear Door Trim.> 3) Remove rear door glass. <Ref. to GW-32, REMOVAL, Rear Door Glass.>...
  • Page 16 REAR DOOR PANEL Exterior Body Panels C: ADJUSTMENT S913364A01 1) Using special tool, loosen body-side bolts of upper and lower hinges to align the position of rear door panel longitudinally and vertically. B5M0933A 2) Loosen door-side bolts of upper and lower hinges to align the position of rear door panel ver- tically and laterally at front-end.

  • Page 17: Rear Sealing Cover

    REAR SEALING COVER Exterior Body Panels 7. Rear Sealing Cover S913565 A: REMOVAL S913565A18 1) Remove rear door trim. <Ref. to EI-27 REMOVAL, Rear Door Trim.> 2) Remove rear speaker. <Ref. ET-13 REMOVAL, Rear Speaker.> 3) Using a spatula, remove sealer. CAUTION: ¼...

  • Page 18: Rear Gate Panel

    REAR GATE PANEL Exterior Body Panels 8. Rear Gate Panel CAUTION: S913363 When the rear gate is released, it may hit and A: REMOVAL damage the body. To prevent this, place a shop S913363A18 cloth between body and gate. 1. REAR GATE PANEL S913363A1801 2.
  • Page 19 REAR GATE PANEL Exterior Body Panels C: DISPOSAL S913363A07 1. GAS STAY S913363A0701 CAUTION: Gas is colorless, odorless, and harmless. However, gas pressure may spray cutting pow- der or oil. Be sure to wear dust-resistant goggles. 1) Cover with a vinyl case as shown in the figure. BO0264 CAUTION: Prevent the vinyl case from being caught by...

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