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2001 forester service manual quick reference index general

1. N N E WS Drain pipe S1M0156A 6 For quick draining open radiator cap CAUTION Be careful not to spill coolant on the floor 7 Drain coolant from reservoir tank 8 Tighten radiator drain screw securely after draining coolant 9 Install reservoir tank to original position 10 Non TURBO model 1 Slowly pour prepared coolant from radiator filler port to neck of filler then pour into reser voir tank up to FULL level Coolant capacity fill up to FULL level MT model Approx 6 4 6 8 US gt 5 6 Imp qt AT model Approx 6 3 6 7 US gt 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 3 Run engine for more than five minutes at 2 000 to 3 000 rpm Run engine until radiator becomes hot in order to purge air trapped in cooling system 4 Stop engine and wait until coolant tempera ture lowers Then open radiator cap to check coolant level and add coolant up to radiator filler neck Next add coolant into reservoir tank up to FULL level 5 After adding coolant securely install radia tor and reservoir tank caps 11 TURBO model 1 Slowly pour prepared coolant fr
2. B4M1674A NOTE If fluid level is at MAX level or above drain fluid to keep the level in the specified range of indicator by using a syringe or the like PM 40 STEERING SYSTEM POWER STEERING Recommended fluid Dexron IIE or III Fluid capacity 0 7 0 7 US qt 0 6 Imp qt 6 POWER STEERING FLUID FOR LEAKS SA07701A1006 Inspect the underside of oil pump and gearbox for power steering system hoses piping and their couplings for fluid leaks If fluid leaks are found correct them by retighten ing their fitting bolts or nuts and or replacing their parts NOTE e Wipe the leakage fluid off after correcting fluid leaks or a wrong diagnosis is taken later e Also pay attention to clearances between hoses or pipings and other parts when inspecting fluid leaks 7 HOSES OF OIL PUMP FOR DAMAGES SA07701A1007 Check pressure hose and return hose of oil pump for crack swell or damage Replace hose with new one if necessary NOTE Prevent hoses from revolving and or turning when installing hoses GI0017 8 POWER STEERING PIPES FOR DAMAGE SA07701A1008 Check power steering pipes for corrosion and damage Replace pipes with new one if necessary Periodic Maintenance Services 9 GEARBOX BOOTS SA07701A1009 Inspect both sides of gearbox boots as follows and correct the defects if necessary 1 A and B positions of gearbox boot are fitted correspondingly in A and B groo
3. Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found Check that the battery tent is securely tightened Lower level GI0086A 13 BRAKE FLUID saoorcso1s Check the brake fluid amount If the amount is insufficient carry out a brake line test to identify brake fluid leaks and check the brake operation After that refill the brake fluid tank with the speci fied type of fluid 14 ENGINE OIL SA09719G5014 Check the engine oil amount If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified engine oil Ou level gauge peA en Engine oil filler cap Upper level Le gt About 1 0 EIF 1 1 US at 0 9 Imp qt gt Lower level GI0087A 15 TRANSMISSION FLUID ses Check the transmission fluid amount If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified fluid u Upper level Lower level a GI0088A 16 AT FRONT DIFFERENTIAL OIL ses Check the AT front differential oil amount If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified AT front differential oil Oil level gauge Upper level Lower level GI0089A PI 7 PRE DELIVERY INSPECTION Pre delivery Inspection 17 COOLANT SA09719G5017 Check the coolant amount on the re
4. 1 When vehicle does not stop Tighten adjusting nut of PHV cable 2 When vehicle does not start properly A When hill holder is released later than engagement of clutch engine tends to stall Loosen adjusting nut gradually until smooth starting is enabled B When hill holder is released earlier than engagement to clutch vehicle slips down slightly Tighten adjusting nut so that hill holder is released later than engagement of clutch status in A Then make adjustment the same as in A NOTE e Whenever turning adjusting nut hold inner cable with pliers to prevent it from turning e Replace pressure hold valve PHV return spring of PHV or PHV cable with new one if they are defective and or damaged Adjusting nut gt Lock nut CH Pressure hold valve GIO115A PM 24 TRANSMISSION OIL 17 Transmission Oil si A REPLACEMENT SA07691A20 1 MANUAL TRANSMISSION saozs1a001 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 8 wes nf H DAN GI0041 2 Reinstall drain plug after draining gear oil and tighten it to the specified torque Tightening torque 44 N m 4 5 kgf m 32 5 ft Ib NOTE e Be sure to place a gasket between the transmis sion case and drain plug e Replace the gasket with a new one e Each oil manufacturer has its base oil and addi
5. 2 Remove filler plug for quick draining oil 3 Reinstall drain plug after draining oil NOTE e Apply fluid packing to drain plug threads before installation in T type e VA type uses a new aluminum gasket Fluid packing Three Bond 1105 Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft lb VA type 34 N m 3 5 kgf m 25 3 ft lb 4 After installing drain plug onto rear differential gear case firmly fill oil up fully to the mouth of filler plug Filler plug Drain plug GI0047A Oil capacity 0 8 0 8 US qt 0 7 Imp qt NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands PM 27 FRONT amp REAR DIFFERENTIAL OIL Periodic Maintenance Services 5 Install filler plug onto rear differential gear case firmly NOTE e Apply fluid packing to filler plug before installa tion in T type e VA type uses a new aluminum gasket Fluid packing Three Bond 1105 Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft lb VA type 34 N m 3 5 kgf m 25 3 ft lb PM 28 BRAKE LINE Periodic Maintenance Services 20 Brake Line sr A INSPECTION sera 1 BRAKE LINE s4rssA000 1 Check scratches swelling corrosion and or traces of fluid leakage on brake hoses or pipe joints 2 Check the possibility of adjacent parts interfer ing with brake pipes hoses during driving and loose connections clamps 3 Check any trace of fluid leakage scrat
6. 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 4 Remove it again and note the reading If the engine oil level is below the L line add oil to bring the level up to the F line AAZ Engine oil filler cap Oil level gauge o Upper level About 1 04 1 1 US qt 0 9 Imp qt o Lower level GI0013A 5 After turning off the engine wait a few minutes for the oil to drain back into the oil pan before checking the level 6 Just after driving or while the engine is warm engine oil level may show in the range between the F line and the notch mark This is caused by thermal expansion of the engine oil 7 To prevent overfilling the engine oil do not add oil above the F line when the engine is cold PM 7 ENGINE OIL FILTER Periodic Maintenance Services 4 Engine Oil Filter sss 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 4 Tighten more approximately 2 3 to 3 4 turn after the seal rubber contacts the oil pump case Do not tighten excessively or oil may leak
7. 4 Check valve is built into vacuum hose Discon nect vacuum hose to inspect function of check valve Blow air into vacuum hose from its brake booster side end Air must flow out of engine side end of hose Next blow air into hose from engine side Air should not flow out of hose Replace both check valve and vacuum hose if check valve is faulty Engine side of vacuum hose is indicated by marking ENGINE as shown Engine side Brake booster side 9 lt ENG gt GI0053A 5 Check vacuum hose for cracks or other dam age NOTE When installing the vacuum hose on the engine and brake booster do not use soapy water or lubri cating oil on their connections 6 Check vacuum hose to make sure it is tight and secure PM 30 BRAKE FLUID Periodic Maintenance Services 21 Brake Fluid s7 A REPLACEMENT soreo 1 Either jack up vehicle and place a safety stand under it or lift up vehicle 2 Remove both front and rear wheels 3 Draw out the brake fluid from master cylinder with syringe 4 Refill reservoir tank with recommended brake fluid Recommended brake fluid FMVSS No 116 fresh DOT3 or 4 brake fluid NOTE e Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid e Be careful not to allow dirt or dust to get into the reservoir tank Bleeding sequence 1 2 gt 3 4 1 4 3 2 GI0054A
8. 5 8 ft lb GI0021A PM 11 CAMSHAFT DRIVE BELT Periodic Maintenance Services 7 Camshaft Drive Belt ss A REPLACEMENT SA07685A20 1 SOHC MODEL SA07685A2001 NOTE For camshaft drive belt replacement procedure details refer to ME SOHC section lt Ref to ME SOHC 46 Timing Belt Assembly gt 1 Remove radiator fan lt Ref to CO 32 Radiator Main Fan and Fan Motor gt and air conditioner fan lt Ref to CO 34 Radiator Sub Fan and Fan Motor gt 2 Remove V belt cover 3 Remove V belts lt Ref to ME SOHC 42 V belt gt 4 Remove air conditioning compressor drive belt tensioner 5 Remove pulley bolt ST 499977100 CRANKSHAFT PULLEY WRENCH 6 Remove crankshaft pulley 7 Remove left side belt cover 8 Remove front belt cover 9 Remove timing belt guide MT vehicle only 10 Turn crankshaft and align alignment marks on crankshaft and left and right camshaft sprockets with notches of belt cover and cylinder block ST 499987500 CRANKSHAFT SOCKET Notch Ges Alignment mark I N Alignment mark Notch d E Mignment mark EN 11 Remove belt idler 12 Remove belt idler No 2 13 Remove timing belt 14 Remove automatic belt tension adjuster assembly 2 DOHC MODEL SA07685A2002 NOTE For camshaft drive belt replacement procedure details refer to ME DOHC section lt Ref to ME SOHC 46 Timing Belt Assembly gt 1 Remove radiator fan and
9. A NOTE SA03676A15 This is information that can improve efficiency of maintenance and assure sound work 1 FASTENER NOTICE sscsez6a1501 Fasteners are used to prevent parts from damage and dislocation due to looseness Fasteners must be tightened to the specified torque Do not apply paint lubricant rust retardant or other substances to the surface around bolts fasteners etc Doing so will make it difficult to obtain the correct torque and result in looseness and other problems 2 STATIC ELECTRICITY DAMAGE seou Do not touch the ECM connectors logic boards and other such parts when there is a risk of static electricity Always use a static electricity prevention cord or touch grounded metal before conducting work 3 IGNITION OFF BATTERY s10se7641508 When removing the battery cables always be sure to turn the ignition off to prevent electrical damage to the ECM from rush current 4 SERVICE PARTS SA03676A 1504 Use authentic service parts for maximum perfor mance and 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 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 veh
10. F point C Safe operating temperature Concentration of coolant 1 100 1 090 1 080 I wo 1 070 oO oO 5 1060F 1 054 N ae e KT 5 1 050 2 1 040 2 5 1 030 Freezing 2 temperature a 1 020 1 010 10 1 000 Go 3020 10 0 10 20 30 40 50 40 22 4 14 32 50 68 86 104 122 Coolant temperature C F GI0037A 3 PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT SA07689A2003 To adjust the concentration of the coolant accord ing to temperature find the proper fluid concentra tion in the above diagram and replace the neces sary amount of coolant with an undiluted solution of SUBARU genuine coolant concentration 50 The amount of coolant that should be replaced can be determined using the diagram Example Assume that the coolant concentration must be increased from 25 to 40 Find point A where the 25 line of coolant concentration intersects with the 40 curve of the necessary coolant concentration and read the scale on the vertical axis of the graph at height A The quantity of cool ant to be drained is 2 1 liters 2 2 US qt 1 8 Imp qt Drain 2 1 liters 2 2 US qt 1 8 Imp qt of cool ant from the cooling system and add 2 1 liters 2 2 US qt 1 8 Imp qt of the undiluted solution of SUBARU coolant If a coolant concentration of 50 is needed drain all the coolant and refill with the undiluted solution only 5 a E 5 Necessary concen
11. in 1 735 68 3 1 765 69 5 2 1 595 62 8 1 585 62 4 Overall height at CW Compartment Length Width Height 1 745 68 7 1 435 56 5 1 245 49 0 1 220 48 0 3 Wheelbase Tread Front Rear Minimum road clearance 1 With bushing bar 2 With fender flare 3 With sunroof 4 Australia spec vehicles B S E NG l N E SA08758G29 Compression rao 8 Firing order 1 3 2 4 Idle speed at Park 700 100 Neutral position Maximum output kW HP rpm 101 137 5 600 130 174 5 600 Maximum torque N m kgf m ft Ib rpm 186 19 0 137 0 3 600 245 25 181 3 200 C ELECTRICAL SA08758G30 Model 2 0 L Non TURBO 2 0 L TURBO Ignition timing at idling speed BTDC rpm 12 10 700 Spark plug Type and manufacturer NGK BK5E 11 without catalyst NGK PFR6B CHAMPION RC10YC4 with catalyst 2 525 99 4 1 475 58 1 1 465 57 7 190 7 5 200 7 9 4 mm mm mm mm mm mm mm mm Generator 12V 75A Type and capacity For Europe 5MT 12 V 48AH SHR 4AT 12 V 52AH For Australia 12 V 40AH Others 12 V 40AH SPC 2 FORESTER Specifications D TRANSMISSION SA08758G31 Model 2 0 L Non TURBO 2 0 L TURBO AWD Transmission type 5MT 1 4AT 2 5MT 1 4AT 2 Clutch type DSPD TCC DSPD TCC 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 4th 5th Reverse
12. lateral link etc e Body parts to which suspensions are installed 3 When toe in and thrust angle are out of stan dard value adjust them so that they conform to respective service standard 6 OIL LEAKAGE OF STRUT enn Visually inspect front strut and rear strut for oil leakage as instructed Replace front strut and rear strut if oil leaks excessively 7 TIGHTNESS OF BOLTS AND NUTS SA07697A 1007 assembly Check bolts and nuts shown in the figure for loose ness Retighten bolts and nuts to specified torque If self lock nuts and bolts are removed replace them with new ones Front suspension lt Ref to FS 2 General Descrip tion gt Rear suspension lt Ref to RS 2 General Descrip tion gt 8 DAMAGE TO SUSPENSION PARTS SA07697A1008 1 Check the following parts and the fastening por tion of the vehicle body for deformation or exces sive rusting which impairs the suspension If necessary replace damaged parts with new ones If minor rust formation pitting etc are noted remove rust and apply remedial anti corrosion measures e Front suspension e Transverse link e Crossmember e Strut e Rear suspension e Lateral link e Crossmember e Strut e In the district where salt is sprayed to melt snow on a road in winter check suspension parts for damage caused by rust every 12 months after lapse of 60 months Take rust prevention measure as required PM 36 WHEEL BEARING Periodic Maintenance S
13. tives Thus do not mix two or more brands 3 Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge Gear oil capacity Single range model 3 5 3 7 US qt 3 1 Imp qt Dual range model 4 0 4 2 US qt 3 5 Imp qt Upper level ia Lower level GI0042A PM 25 Periodic Maintenance Services ATF Periodic Maintenance Services 18 ATF son A REPLACEMENT SA07692A20 1 AUTOMATIC TRANSMISSION FLUID SA07692A2001 1 Drain ATF Automatic Transmission Fluid by removing drain plug after allowing the engine to cool for 3 to 4 hours NOTE Before starting work cool off the engine well Q y ATF drain plug MSC es Front differential I N drain plug y men B m il GI0043A 2 Reinstall drain plug after draining ATF and tighten it to the specified torque Tightening torque 25 0 N m 2 55 kgf m 18 4 ft lb 3 Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole Recommended fluid Dexron Ill type automatic transmission fluid Fluid capacity Fill the same amount drained from ATF drain plug hole 4 Run the vehicle until the ATF temperature rises to 60 to 80 C 140 to 176 F and check the ATF level GI0044A 2 D ATF Fl LT E R SA07692A2002 NOTE ATF filter is maintenance free part ATF filter needs replacement when it has physically damaged o
14. turn steering wheel 90 in both the left and right direc tions While wheel is being rotated reach under vehicle and check for looseness in gearbox Tightening torque 59 N m 6 0 kgf m 43 4 ft Ib AOE Bag Sek N e L gt 5 Z Gearbox mounting bolts th AN L 5 111118 x Te GI0076A 2 Check boot for damage cracks or deterioration PM 39 STEERING SYSTEM POWER STEERING Periodic Maintenance Services 3 With vehicle on a level surface quickly turn steering wheel to the left and right While steering wheel is being rotated check the gear backlash If any unusual noise is noticed adjust the gear backlash in the following manner 1 Loosen the adjusting screw three to four rotations 2 Apply liquid packing to at least 1 3 of entire perimeter of adjusting screw thread 3 Tighten adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft lb and then loosen Repeat this operation twice 4 Retighten adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft lb and back off 25 Ja SSC Apply liquid packing to at least 1 3 of entire perimeter G10077A 5 Install lock nut While holding adjusting screw with a wrench tighten lock nut using ST ST 926230000 SPANNER Tightening torque Lock nut 39 N m 4 0 kgf m 29 ft lb Hold the adjusting screw with a wrench to pre vent it from turning while tightening the lock nut 4 TI E ROD SA07701A1004 1 Check tie rod
15. 19 ft lb NOTE e Be sure to place the gasket between the cylin der head and spark plug e H torque wrench is not available tighten spark plug until gasket contacts cylinder head then Periodic Maintenance Services tighten further 1 4 to 1 2 turns 2 TURBO MODEL SA07683A2004 NOTE For spark plug replacement procedure details refer to IG section Pei to IG DOHC TURBO 4 Spark Plug gt 1 Disconnect battery ground cable and then remove battery and battery carrier 2 Remove air cleaner lower case lt Ref to IN DOHC TURBO 7 Air Cleaner gt 3 Remove washer tank and put it aside 4 Disconnect connector from ignition coil 5 Remove ignition coil 6 Remove spark plug with a plug wrench EN0859 7 Set new spark plug Recommended spark plug NGK PFR6B 8 Tighten spark plug lightly with hand and then secure with a plug wrench to the specified torque Tightening torque Spark plug 21 N m 2 1 kgf m 15 ft lb Ignition coil 16 N m 1 63 kgf m 11 8 ft lb NOTE e Be sure to place the gasket between the cylin der head and spark plug e f torque wrench is not available tighten spark plug until gasket contacts cylinder head then tighten further 1 4 to 1 2 turns PM 9 DRIVE BELT S Periodic Maintenance Services 6 Drive Belt S s A INSPECTION SA07684A10 1 Replace belts if cracks fraying or wear is found 2 Check drive belt tension and adjust it if neces sary by ch
16. Engine case Transmission Rear differential Rear differential Cemedine 3000 RS 300 Recommended Three Bond 1215B Three Bond 1217B Three Bond 1324 Three Bond 1105 Armstrong s Eastman 910 004403010 Dow Corning s No 7038 Weatherstrip Starcalking B 33A 000018901 Butyl Rubber sealant Steering adjusting screw SOHC cam cap Three Bond 1102 Three Bond 1280B RM 6 004403006 K0877YA018 PRE DELIVERY INSPECTION PI Page 1 Pre delivery JEE eege wesen ee 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 e Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state e Check if the vehicle before delivery is in a nor mal state e Check for any damage or missing parts that may have taken place during transportation or storage e Make sure to provide a complete vehicle to the customer Because of the above reasons all dealerships must always carry out the PDIs before delivering a vehicle In addition all franchised shops and PDI centers must check the status of every vehicle received to identify who is responsible for any possible defects PI 2 PRE DELIVERY INSPECTION Pre delivery Inspection B PDI PROCEDURE swe Follow the procedures shown in the table b
17. Front right Rear left Front left Rear right Secondary Primary zZ YS NH 4 2 3 4 5 6 L ee en en eieer 5 Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid GI0055 NOTE e Cover bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts e During bleeding operation keep the brake reserve tank filled with brake fluid to eliminate entry of air e Brake pedal operation must be very slow e For convenience and safety it is advisable to have two men working e The amount of brake fluid required is approxi mately 500 m 16 9 US fl oz 17 6 Imp fl oz for total brake system 6 Instruct your co worker to depress the brake pedal slowly two or three times and then hold it depressed 7 Loosen bleeder screw approximately 1 4 turn until a small amount of brake fluid drains into container and then quickly tighten screw 8 Repeat steps 6 and 7 above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube NOTE Add brake fluid as necessary while performing the air bleed operation in order to prevent the tank from running short of brake fluid 9 After completing the bleeding operation hold brake pedal depressed and tighten screw and install bleeder cap Tightening torque 8 N m 0 8 kgf m 5 8 ft Ib 10 Bleed air
18. H S TI R E SA08758G35 Rim size 15 x 6J 16 x 6 JJ Tire size 205 70R15 215 60R16 Steel belted radial Tubeless i CAPACITY SA08758G36 2 0 L Non TURBO 2 0 L TURBO SMT Upper level US qt Imp qt 4 5 4 8 4 0 5 0 5 3 4 4 Lower level US qt Imp qt 3 5 3 7 3 1 4 0 4 2 3 5 Transmission gear oil US qt Imp at 4 0 4 2 3 5 3 5 3 7 3 1 Automatic transmission fluid US qt Imp qt 8 4 8 9 7 4 9 3 9 8 8 2 AT differential gear oil US qt Imp qt 1 2 1 3 1 1 1 2 1 3 1 1 AWD rear differential gear oil US qt Imp qt 0 8 0 8 0 6 0 8 0 8 0 6 Power steering fluid US qt Imp qt 0 7 0 7 0 6 0 7 0 7 0 6 Engine coolant US qt Imp qt 6 3 6 7 5 5 6 3 6 7 5 5 4 4 4 4 SPC 4 FORESTER Specifications J WEIGHT SA08758G37 1 EXCEPT AUSTRALIA SPEC VEHICLE s475s63706 2 0 L Non TURBO AWD SMT 4AT 5MT 4AT Curb weight CW 730 1 610 745 1 643 745 1 643 760 1 676 615 1 356 615 1 356 620 1 367 620 1 367 1 345 2 966 1 360 2 999 1 365 3 010 1 380 3 043 Maximum permissible axle weight MPAW 920 2 029 930 2 051 1 890 4 163 920 2 029 1 875 4 134 2 0 L TURBO 930 2 051 1 890 4 167 AWD SMT 4AT 5MT 4AT Curb weight CW 795 1 753 815 1
19. SA09719G5032 Check the clock for normal operations and enough accuracy Pre delivery Inspection 30 RADIO SA09719G5033 Check the radio for full functionality and normal noise level Also check the CD unit operations 31 CIGARETTE LIGHTER s47 s650s Check that the cigarette lighter operations 32 LIGHTING SYSTEM 407165035 e Check the headlight operations e Check the brake light operations e Check the other lights for normal operations 33 WINDOW WASHER ses Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure Front 300 mm SC d 530 mm 370 mm 14 57 in 20 87 in 370 as Ss 14 57 in d 820 mm 32 28 in S1M0146A 1 100 mm 3 94 in 120 mm 4 72 in eS ir S1M0147A 34 WIPER SA09719G5037 Check the front and rear wipers for normal opera tions 35 POWER WINDOW OPERATION CHECK SA09719G5004 Manipulate the power window switches one by one to check that each of the power windows goes up and down with no abnormal noises 36 BRAKE TEST SA09719G5038 Check the foot brake for normal operations 37 PARKING BRAKE sasriscsoss Check the parking brake for normal operations PI 9 PRE DELIVERY INSPECTION Pre delivery Inspection 38 AT SHIFT CONTROL eco Set the AT select lever to each gear position while checking that the demanded gear position is co
20. THIS MANUALS How to Use This Manuals 1 How to Use This Manuals 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 The specification maintenance and other information for the components are included and diagnosis information has also been added where necessary 2 D l N D EX SA02675F6902 The first page has an index with tabs And at the end of each section is an alphabetical index 3 COMPONENTS SA02675F6903 For each component a composition drawing is included 4 SPECIFICATIONS SA02675F6904 If necessary specifications are also included 5 INSPECTION SA02675F6905 Inspections are included to be carried out before and after maintenance 6 MAINTENANCE SA02675F6906 Maintenance instructions are provided for each component When multiple components comprise one process refer to the instructions for that pro cess for each component 7 DIAGN OSIS SA02675F6907 Tables showing a step by step process make it easy to conduct diagnosis 8 SI UNITS SA02675F6909 Measurements in these manuals are according to the SI units Metric and yard pound measurements are also included HU 2 SPECIFICATIONS FORESTER Specifications 1 Forester ser A DIMENSIONS s ssc2 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
21. age or poor operation of the engine and fuel injec tion system Use the specified gasoline to correct performance e Unleaded gasoline Use unleaded gasoline and not leaded gasoline on vehicles with catalytic converter installed to reduce air pollution Using leaded gasoline will damage the catalytic converter e Leaded gasoline On vehicles without catalytic converter use gaso line with an octane value of 90 RON or higher RM 2 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 G4 or G5 A1 A2 or A3 API SH or SG G10001 GI0002 Manual transmission oil Front differential Rear differential SAE viscosity SAE viscosity No and applicable temperature SAE J300 10 50 10W 30 or 10W 40 gt 5W 30 Recommend GI0003A RM 3 RECOMMENDED MATERIALS Recommended Materials SAE viscosity SAE viscosity No and applicable temperature SAE J300 Manual transmission oil CC 30 20 10 CF 22 4 14 Rear differential GI0004A Front differential GI0005A 4 FLUID SA05678G2204 Use the fluids specified in the table below Do not
22. air conditioning fan lt Ref to CO 32 Radiator Main Fan and Fan Motor gt and lt Ref to CO 34 Radiator Sub Fan and Fan Motor gt 2 Remove V belts lt Ref to ME DOHC TURBO 44 V belt gt 3 Remove air conditioning compressor drive belt tensioner 4 Remove pulley bolt ST 499977300 CRANKSHAFT PULLEY WRENCH 5 Remove crankshaft pulley 6 Remove air conditioning compressor drive belt tensioner 7 Remove left side belt cover 8 Remove right side belt cover 9 Remove front belt cover 10 Remove timing belt guide MT vehicle only 11 Turn crankshaft and align alignment marks on crankshaft and left and right camshaft sprockets with notches of belt cover and cylinder block To turn crankshaft Use ST ST 499987500 CRANKSHAFT SOCKET Notch Notch mark S1M0150A 12 Remove belt idler 13 Remove timing belt 14 Remove automatic belt tension adjuster assembly PM 12 CAMSHAFT DRIVE BELT B INSTALLATION sor 1 SOHC MODEL SA07685A1101 Install in the reverse order of removal lt Ref to ME SOHC 46 Timing Belt Assembly gt 2 DOHC MODEL SA07685A1102 Install in the reverse order of removal lt Ref to ME DOHC TURBO 48 Timing Belt Assembly gt NOTE When installing the timing belt be sure to align all alignment marks on the belt with corresponding marks on the sprockets If incorrectly installed interference between pistons and valves may occur Periodic Maint
23. e Europe Australia and General Except GCC JF1SF5LJ31G002001 The starting and ending brackets are stop marks Meaning Details Manufacturer body area JF1 Passenger car FHI made JF2 MPV FHI made Car line Forester Body type Wagon Displacement 2 0 L AWD Steering position Engine amp transmission RHD Right hand drive LHD Left hand drive SOHC MPI Full time AWD 5 speed MT SOHC MPI 4 speed AT DOHC Turbo 4 speed AT Drive type Full time AWD 5 speed MT single range Full time AWD 5 speed MT dual range Full time AWD 4 speed AT 2001MY 2002MY F 5 K L J R D DOHC Turbo Full time AWD 5 speed MT P 3 4 5 1 2 G FHI Gunma 10 Model year 11 G Factory location 12 to 17 002001 Serial number e GCC countries Saudi Arabia etc JF1SF53MX1J002001 The starting and ending brackets are stop marks Meaning Details Manufacturer body area JF1 Passenger car FHI made Car line Forester Body type E Wagon Displacement 5 2 0 LAWD Grade 3 BASE 5 NA SPRT Restraint M Manual belts dual airbag Check digit Model year 1 2001MY 2 2002MY Transmission type 002001 Serial number 12 to 17 H Full time AWD 4 speed AT J Full time AWD 5 speed MT dual range ID 4 IDENTIFICATION Identification 3 MODEL NUMBER PLATE eem The m
24. from each wheel cylinder by follow ing the previous 5 steps 11 Depress brake pedal with a force of approxi mately 294 N 30 kgf 66 Ib and hold it there for approximately 20 seconds At this time check pedal to see if it makes any unusual movement Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage 12 Install wheels and drive vehicle for a short distance between 2 to 3 km 1 to 2 miles to make sure that brakes are operating properly PM 31 DISC BRAKE PADS AND DISCS Periodic Maintenance Services 22 Disc Brake Pads and Discs SA07695 A INSPECTION ser 1 DISC BRAKE PAD AND DISC senn 1 Jack up vehicle and support with rigid racks Then remove wheels 2 Visually check pad thickness through inspec tion hole of disc brake assembly Replace pad if necessary Ze Inspection hole GI0056A Pad thickness including back metal mm in Front Rear 17 0 67 14 0 55 7 5 0 295 6 5 0 256 Service limit 1 5 0 059 1 5 0 059 exclusive back metal Thickness of pad Lining aa e 2 Back D K metal GI0057A 3 Check the disc rotor and correct or replace if it is damaged or worn Brake disc thickness mm in EE OE Rear 24 0 94 10 0 39 22 0 87 8 5 0 335 4 Measure the disc rotor runout at a point less than 5 mm 0 20 in from the outer periphery of the rotor Disc rotor runout limit Front 0 075 mm 0 0
25. 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 NT 5 NOTE Note MEMO NT 6 IDENTIFICATION IDENTIFICATION Identification 1 Identification SA06679 A IDENTIFICATION SA06679F70 1 IDENTIFICATION NUMBER AND LABEL LOCATIONS eem The VIN Vehicle Identification Numbers is used to classify the vehicle Positioning of the plate label for identification Emission control label I Vehicle identification number ID plate Europe model ADR compliance plate Australia model _ Tire inflation pressure label ES Driver side Saudi Arabia plate Saudi Arabia model a Built date plate Australia model S1M0148A Transmission serial number ENGINE AAT Engine serial number GI0007A GI0009A ID 2 IDENTIFICATION Identification Stamp location EN ES G10008A S1M0149A Model number plate SEZ FUJI HEAVY INDUSTRIES LTD u a 4 2 UF BDAlLleloRlelolol2Iolol EE Haas Size EJOJ am code ALTO engine ype ES O EINMIAIBIA Gator code 21310 ransmission type LMI7ISI2 RIGTAJAJA Sgr GIOO11A ID 3 IDENTIFICATION Identification 2 MEANING OF VIN SA06679F7002 The meaning of the VIN is as follows
26. that the child lock operates normally 9 Accessory check Check the following accessories are provided Owner s manual Warranty booklet Service booklet Spare key Jack Tool set Spare tire 10 Operation check of hood lock release system 1 Operate the hood lock release lever to check that the hood opens nor mally 11 Connection of air conditioner harness 1 If the vehicle is about to be delivered to the customer connect the air conditioner harness 12 Battery 1 Check the battery for any abnormal conditions such as rust and trace of battery fluid leaks 13 Brake fluid 1 Check the fluid amount 14 Engine oil 1 Check the oil amount 4 2 For AT check the front differential oil 1 1 2 Check the seat installation conditions and functionality PI 3 PRE DELIVERY INSPECTION Pre delivery Inspection Checks with the Engine Running Step Check point Read memory and test mode connectors Read memory and test mode connectors Starting condition Start the engine and check that the engine starts smoothly Exhaust system heck that the exhaust noise is normal and no leaks are found Indicator light heck that all the indicator lights operate normally Clock heck that the clock operate normally Radio heck that the radio system operates normally Cigarette lighter heck that the cigarette lighter operates normally Lighting system heck that the lighting systems operate nor
27. 030 in Rear 0 075 mm 0 0030 in NOTE When replacing a pad always replace the pads for both the left and right wheels at the same time Also replace pad clips if they are twisted or worn GI0058 PM 32 BRAKE LININGS AND DRUMS Periodic Maintenance Services 23 Brake Linings and Drums SA07696 A INSPECTION sera 1 REAR DRUM BRAKE een 1 Remove brake drum and check that there is no fluid leakage from wheel cylinder If there is fluid leakage from wheel cylinder replace it lt Ref to BR 34 Rear Drum Brake Drum gt 2 Inspect brake shoes for damage or deformities and check brake linings for wear NOTE e Always replace both leading and trailing brake shoes for the left and right wheels at the same time e When either the left or the right brake assembly is replaced always replace the leading shoe and trailing shoe of the other e The cotter pin once removed cannot be reused Thickness of lining except back metal Standard value 4 1 mm 0 161 in Service limit 1 5 mm 0 059 in GI0059A Rotational direction of drum Forward Wheel cylinder Upper shoe return spring Adjusting lever Trailing shoe Lower shoe return spring 4 2 3 4 5 6 7 Leading shoe ee EN a ee rere vr ONS NS To replace trailing shoe remove cotter pin Clevis pin should also be replaced if worn 3 Check brake drum for wear dents or other damage If the inside surface of brake d
28. 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION SECTION FOREWORD HOW TO USE THIS MANUAL SPECIFICATIONS PRECAUTION 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 NOTE IDENTIFICATION RECOMMENDED MATERIALS PRE DELIVERY INSPECTION PERIODICAL MAINTENANCE 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 G8050GE1 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX ENGINE1 SECTION EMISSION CONTROL FUEL INJECTION FUEL SYSTEMS FU SOHC AUX EMISSION CONTROL DEVICES EC SOHC INTAKE INDUCTION IN SOHC MECHANICAL ME SOHC This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of
29. 5 After installing oil filter run engine and make sure that no oil is leaking around seal rubber NOTE The filter element and filter case are permanently joined therefore interior cleaning is not necessary 6 Check the engine oil level lt Ref to PI Z ENGINE OIL PDI PROCEDURE Pre delivery Inspection gt PM 8 SPARK PLUGS 5 Spark Plugs sr A REPLACEMENT sore 1 NON TURBO MODEL SA07683A2003 NOTE For spark plug replacement procedure details refer to IG section lt Ref to IG SOHC 4 Spark Plug gt and lt Ref to IG SOHCw oOBD 5 Spark Plug gt 1 Disconnect battery ground cable Remove air intake duct as a unit 3 Remove resonator chamber 4 Remove washer tank and put it aside 5 Disconnect spark plug cord 6 Remove spark plug with a plug wrench Ce DEE El GI0018 7 Set new spark plug Recommended spark plug With OBD CHAMPION RC10YC4 CHAMPION RC8YC4 NGK BKR6E 11 NIPPONDENSO K20PR U11 Spark plug gap 1 0 1 1 mm 0 039 0 043 in Without OBD NGK BKR6E Without catalytic converter CHAMPION RC10YC4 With catalytic con verter NGK BKR5E 11 With catalytic converter Spark plug gap 0 7 0 8 mm 0 028 0 031 in Without catalytic converter 1 0 1 1 mm 0 039 0 043 in With catalytic converter 8 Tighten spark plug lightly with hand and then secure with a plug wrench to the specified torque Tightening torque 20 6 N m 2 10 kgf m 15
30. 797 790 1 742 810 1 786 Rear 635 1 400 630 1 389 630 1 389 630 1 389 Total 1 430 3 153 1 445 3 186 1 420 3 131 1 440 3 185 Maximum permissible axle weight MPAW Maximum permissible weight MPW NOTE When any of the following optional parts are installed add the weight to the curb weight Weight of optional parts Front Total 975 2 150 995 2 195 975 2 150 975 2 150 1 010 2 225 1 010 2 225 1 010 2 225 1 010 2 225 1 950 4 300 Self levelizer Cruise control Air con ditioner 1 970 4 344 Sunroof SRS airbag Driver amp 1 950 4 300 Passen ger SRS airbag Side Cold weather pack 1 970 4 344 Cold weather pack Leather seat Front kg lb 2 6 5 7 Rear kg Ib Total kg lb SPC 5 Specifications FORESTER 2 AUSTRALIA SPEC VEHICLE s407586370 Unladen mass UM Gross vehicle mass GVM NOTE Front Rear 2 0 L Non TURBO 2 0 L TURBO AWD AWD RHD RHD kg Ib kg Ib 740 1 632 625 1 378 755 1 665 625 1 378 810 1 786 630 1 389 835 1 841 625 1 378 When any of the following optional parts are installed add the weight to the unladen mass Weight of optional parts Front kg Ib Cruise control Self levelizer Air condi tioner Fog la
31. ANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM HEATER VENTILATOR AND A C AIRBAG SYSTEM SEAT BELT SYSTEM LIGHTING SYSTEM 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 WIPER AND WASHER SYSTEMS ENTERTAINMENT COMMUNICATION SYSTEM GLASS WINDOWS MIRRORS BODY STRUCTURE INSTRUMENTATION DRIVER INFO IDI SEATS SE SECURITY AND LOCKS SL SUNROOF T TOP CONVERTIBLE TOP SR SUNROOF EXTERIOR INTERIOR TRIM El EXTERIOR BODY PANELS EB CRUISE CONTROL SYSTEM cc 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 G8050GE6 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION AIRBAG SYSTEM DIAGNOSTICS AB CRUISE CONTROL SYSTEM DIAGNOSTICS cc IMMOBILIZER DIAGNOSTICS G8050GE6 2001
32. Auxiliary transmission gear ratio High Low Reduction gear 1st reduction Type of gear Helical Helical Front drive Gear ratio 1 000 1 000 Final reduction Type of gear Hypoid Hypoid Hypoid Gear ratio 4 444 4 444 4 111 Reduction gear Transfer reduc Type of gear Hypoid Rear drive tion Gear ratio 1 081 4 1 000 5 Final reduction Type of gear Hypoid Hypoid Hypoid Gear ratio 4 444 4 111 4 4 444 5 4 111 5MT 1 5 x 2 forward speeds with synchromesh and 1 reverse with center differential and viscous coupling 4AT 2 Electronically controlled fully automatic 4 forward speeds and 1 reverse with hydraulically controlled transfer clutch 5MT 3 5 forward speeds with synchromesh and 1 reverse with center differential and viscous coupling DSPD Dry Single Plate Diaphragm TCC Torque Converter Clutch 4 For Europe 5 Others E STE E R NG SA08758G32 Rack and Pinion Turns lock to lock Minimum turning circle m ft Curb to curb 10 8 35 4 F SUSPENSION SA08758G33 MacPherson strut type Independent Coil spring Dual link strut type Independent Coil spring SPC 3 FORESTER Specifications G i B RAK E 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
33. Boots amp Joints een 38 27 Steering System Power Steering EE og 28 Supplemental Restraint System EEN 42 GENERAL DESCRIPTION Periodic Maintenance Services 1 General Description svv A GENERAL SA07001G23 Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious PM 2 SCHEDULE Periodic Maintenance Services 2 Schedule SA07682 A MAINTENANCE SCHEDULE 1 een 1 MAINTENANCE SCHEDULE 1 1 eegen 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 Maintenance Interval Number of months or km miles whichever occurs first Months Remarks x 1 000 km x 1 000 miles Engine oil Engine oil filter 2 MAINTENANCE SCHEDULE 1 2 siorsec2o2 For periodic maintenance of over 100 000 km 60 000 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 100 000 km 60 000 miles or 48 months Maintenance Interval Number of months or km miles whichever occurs first Months Remarks x 1 000 km x 1 000 miles Spark plugs Drive belt s Valve clearance Use in Europe coun Inspect ever
34. CK THE DOOR OPERATIONS LOCK UNLOCK AND OPEN CLOSE AS FOLLOWS SA09719G5003 Using the key lock and unlock the door several times to check for normal operation Open and close the door several times for smooth move ment e Vehicles with manual door locks Sit in the driver seat close the door completely and move the lock lever to the lock position Then pull the inside door handle to ensure the door will not open GI0078A e Vehicles with power door locks Sit in the driver seat close the driver s door completely and place the door lock knob A to the lock position Then pull the all inside door handles B to ensure that the all doors will not open For other doors place the lock levers to the lock positions and then pull the inside door handles to ensure that the doors will not open S1M0145A 5 OPERATION CHECK OF TRUNK LOCK RELEASE LEVER SA09719G5005 Operate the trunk lock release lever and verify that the trunk lid opens PRE DELIVERY INSPECTION Pre delivery Inspection 6 OPERATION CHECK OF REAR GATE LOCK RELEASE LEVER srooroosoe e Operate the rear gate lock release lever and verify that the rear gate is unlocked and opened smoothly e Using the key lock and unlock the door several times to check for normal operation Open and close the door several times for smooth move ment 7 OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER sem Operate the fuel lid opener and ve
35. FORESTER SERVICE MANUAL QUICK REFERENCE INDEX WIRING SYSTEM SECTION WIRING SYSTEM WI 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 G8050GE7 FOREWORD FOREWORD Foreword 1 Foreword svs A FOREWORD SA01674G21 These manuals are used when performing maintenance repair or diagnosis of the Subaru Forester Applied model SF from 2001 MY 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 Changes in specifications methods etc may be made without notice FW 2 HOW TO USE THIS MANUALS HU Pags 1 How to Use This Manual HOW TO USE
36. Full time AWD AT MPT Classification Series 75 MT 1A New AT 3 AT 5 MT Transmission specifica tions V Full time AWD 5 speed MT with viscous coupling center differential single range X Full time AWD 5 speed MT with viscous coupling center differential dual range Z Full time AWD 4 speed AT with MPT e Rear differential 1 VA1RFF Detailed specifications Meaning Used when ordering parts See the parts catalog for details Details For AWD Type Hypoid gear diameter 1 152 dia 2 160 dia Installation position R Rear Reduction gear ratio F 4 444 Specification differences F Case A e Rear differential 2 T1 Reduction gear ratio 3 900 No 4 111 No 4 444 No 4 111 No 4 111 Strengthened type 4 444 Strengthened type 3 700 No ID 6 RECOMMENDED MATERIALS RM Page 1 Recommended Materials 44 ennnenanennnnnnnnn enen eren eren nennen RECOMMENDED MATERIALS Recommended Materials 1 Recommended Materials s s A RECOMMENDED MATERIALS SA05678G22 1 D GENERAL SA05678G2201 To insure the best performance always use the specified oil gasoline adhesive sealant etc or that of equivalent quality 2 FU E L SA05678G2202 Always use a gasoline of the same or higher octane value than specified in the owner s manual Ignoring the specifications below will result in dam
37. GI0062A 3 If the deformation or wear of back plate shoe etc is noticeable replace them 4 When the shoe return spring tension is exces sively weakened replace it taking care to identify upper and lower springs B ADJUSTMENT ser 1 REAR DRUM BRAKE eeng The main brake is adjusted automatically and so there is no need to adjust it 2 PARKING BRAKE REAR DISC BRAKE SA07696A0102 For rear disc brake adjust parking brake after bleeding the air 1 Remove rear cover rubber installed at back plate 2 Turn adjuster toward arrow mark upward until it is locked slightly by using slot type screwdriver as shown in illustration Adjuster All I Cover rubber Slot type screwdriver Back plate GI0063A 3 Turn back downward adjuster 3 to 4 notches 4 Install cover rubber at original position cor rectly PM 34 SUSPENSION Periodic Maintenance Services 24 Suspension svs A INSPECTION s1710 1 SUSPENSION BALL JOINT eau 1 Jack up vehicle until front wheels are off ground 2 Next grasp bottom of tire and move it in and out If relative movement is observed between brake disc cover and end of transverse link ball joint may be excessively worn 3 Next grasp end of transverse link and move it up and down Relative movement between hous ing and transverse link boss indicates ball joint may be excessively worn 4 If relative movement is observed in
38. PECTION AND ADJUSTMENT SA07690G26 1 MECHANICAL CLUTCH TYPE saoreooozeo 1 Inspect free play of clutch pedal by operating pedal by hand If it is out of the specified value adjust it by turn ing wing nut on engine side of clutch cable at release fork Tightening torque Adjusting nut on release fork 4 4 7 4 N m 0 45 0 75 kgf m 3 3 5 4 ft Ib Standard free play AT clutch pedal 10 20 mm 0 39 0 79 in ORT 2 2 gt Free play 10 20mm 0 39 0 79in GI0144 Fork lever free play allowance 2 4 mm 0 08 0 16 in Free play Full stroke 2 4mm 25 5mm 1 in 0 08 0 16in Lock nut Adjusting nut 7 Release fork Gl0145 2 Pedal to floor plate gap in disengaged position 1 With the engine idling pull parking brake lever completely 2 Slowly depress clutch pedal while moving shift lever into reverse 3 Stop depressing clutch pedal when gear shifting is complete With clutch pedal in this position measure the distance between the upper side of pedal pad and the lower end of front panel intersection of front panel with floor Check that the measured value is within the specified standard Standard 80 mm 3 15 in or more 3 Pedal height Check that the clutch pedal pad surface is level with or higher than brake pedal pad surface 2 HYDRAULIC CLUTCH TYPE enen 1 Push the release lever to retract the push rod of the
39. 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 EXHAUST EX SOHC COOLING GO LUBRICATION LU SPEED CONTROL SYSTEMS SP IGNITION IG SOHC STARTING CHARGING SYSTEMS SC ENGINE DIAGNOSTICS EN SOHC 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 G8050GE2 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX ENGINE2 SECTION FUEL INJECTION FUEL SYSTEMS FU SOHCw oOBD EMISSION CONTROL AUX EMISSION CONTROL DEVICES EC SOHCw oOBD EXHAUST EX SOHCw 00OBD IGNITION IG SOHCw 00BD 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 ut
40. al when per forming maintenance on airbag components or nearby and airbag wiring harnesses or nearby To prevent unexpected deployment perform one of the steps below and then wait at least 20 sec onds to discharge electricity before beginning work e Step 1 Turn the ignition switch OFF e Step 2 Remove the negative battery terminal 6 AIRBAG DISPOSAL SA04677F5906 To prevent bodily injury from unexpected airbag deployment do not dispose airbag modules in the same way as other refuse Follow the special instructions for disposal in this manual Follow all government regulations concerning disposal of refuse 7 AIRBAG MODULE SA04677F5907 Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment e Do not hold harnesses or connectors to carry the module e Do not face the bag in the direction that it opens towards yourself or other people e Do not face the bag in the direction that it opens towards the floor or walls 8 AIRBAG SPECIAL TOOLS erem To prevent unexpected deployment only use spe cial tools 9 WINDOW SA04677F5909 Always wear safety glasses when working around any glass to prevent glass fragments from damag ing your eyes 10 WINDOW ADHESIVE zen Always use the specified urethane adhesive when attaching glass to prevent it from coming loose and falling resulting in accidents and injury PC 2 NOTE NOTE Note 1 Note
41. alve open pressure using radiator cap tester NOTE Rust or dirt on cap may prevent valve from func tioning normally be sure to clean cap before test ing Raise the pressure until the needle of gauge stops and see if the pressure can be retained for five to six seconds The radiator cap is normal if a pres sure above the service limit value has been main tained for this period Radiator cap valve open pressure Standard value 93 123 kPa 0 95 1 25 kg cm 14 18 psi Service limit 83 kPa 0 85 kg cm 12 psi GI0034 Deformation damage rust Crack deformation GI0035A 3 If the coolant temperature exceeds 76 0 to 80 0 C 169 to 176 F while radiator is not so hot check thermostat If thermostat does not open at 76 0 to 80 0 C 169 to 176 F replace it with a new one 4 If electric fan does not operate when coolant temperature exceeds 90 to 94 C 194 to 201 F check thermoswitch or fan motor PM 18 COOLANT Periodic Maintenance Services 13 Coolant SA07689 A REPLACEMENT svr 1 REPLACEMENT OF COOLANT eens WARNING The radiator is of the pressurized type Do not attempt to open the radiator cap immediately after the engine has been stopped 1 Lift up the vehicle 2 Remove under cover 3 Fit vinyl tube to drain pipe 4 Place a container under drain tube 5 Loosen drain cock to drain engine coolant into container y Drain cock
42. and engine compartment piping for rust hose damage loose bands etc If faulty parts are found repair or replace them lt Ref to FU SOHC 69 Fuel Delivery Return and Evaporation Lines gt or lt Ref to FU SOHCw oOBD 56 Fuel Delivery Return and Evaporation Lines gt or lt Ref to FU DOHC TURBO 67 Fuel Delivery Return and Evaporation Lines gt PM 15 FUEL FILTER Periodic Maintenance Services 10 Fuel Filter SA07027 A REPLACEMENT SA07027A20 For fuel filter replacement procedures refer to FU section lt Ref to FU SOHC 66 Fuel Filter gt or lt Ref to FU SOHCw oOBD 54 Fuel Filter gt or lt Ref to FU DOHC TURBO 64 Fuel Filter gt PM 16 AIR CLEANER ELEMENT 11 Air Cleaner Element seer 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 It is resistant to cold weather and has a long service life Dirt adhering to this filter paper forms porous laminations with the viscous liquid which function as a filtration layer to reduce dust penetra tion into the filter paper If this filter paper is cleaned the filtration layer thus formed will be lost along with the viscous liquid 1 NON TURBO MODEL SA07687A2001 TE M _ EZ W s D ZC a D 57 ED j GI0032 1 Remove bolt A which install air cleaner case to stay
43. and tie rod ends for bends scratches or other damage Tie rod end Knuckle arm GI0105A 2 Check connections of knuckle ball joints for play inspect for damage on dust seals and check free play of ball studs If castle nut is loose retighten it to the specified torque then tighten fur ther up to 60 until cotter pin hole is aligned Tightening torque 27 N m 2 75 kgf m 19 9 ft lb 3 Check lock nut on the tie rod end for tightness If it is loose retighten it to the specified torque Tightening torque 83 N m 8 5 kgf m 61 5 ft lb 5 POWER STEERING FLUID LEVEL SA07701A1005 1 Check power steering fluid for deterioration or contamination If the fluid is highly deteriorated or contaminated drain it and refill with new fluid 2 Check joints and units for oil leakage If any oil leaks are found repair or replace the applicable part 3 Inspect fluid level on flat and level surface with engine OFF by indicator of reservoir tank If the level is at lower point or below add fluid to keep the level in the specified range of the indica tor If at upper point or above drain fluid by using a syringe or the like 1 Check at temperature 20 C 68 F on res ervoir surface of oil pump read the fluid level on the COLD side 2 Check at temperature 80 C 176 F on res ervoir surface of oil pump read the fluid level on the HOT side Non turbo model H4M1007
44. anging generator installing position and or idler pulley installing position Belt tension A replaced 7 9 mm 0 276 0 354 in reused 9 0 10 0 mm 0 354 0 394 in B replaced 7 5 8 5 mm 0 295 0 335 in reused 9 0 10 0 mm 0 354 0 394 in There is no belt B on models without an air conditioner 98 N 10 kg 22 Ib GI0019A C P Crankshaft pulley GEN Generator P S Power steering oil pump pulley A C Air conditioning compressor pulley IP Idler pulley B REPLACEMENT sro NOTE Wipe off any oil or water on the belt and pulley 1 Loosen the lock bolt A 2 Loosen the slider bolt B 3 Remove the front side belt C GI0021A 4 Loosen the lock nut A 5 Loosen the slider bolt B 6 Remove the rear side belt a est GL af GI0022A A 7 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension 8 Tighten the slider bolt B 9 Tighten the lock nut A Tightening torque 22 6 N m 2 3 kgf m 16 6 ft Ib e est A af GI0022A 10 Install anew belt and tighten the slider bolt so as to obtain the specified belt tension 11 Tighten the slider bolt B 12 Tighten the lock bolt A PM 10 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
45. ches etc on master cylinder wheel cylinder and pres sure control valve NOTE e When the brake fluid level in the reservoir tank is lower than the specified limit the brake fluid warning light on the combination meter will come on e Visually check brake hose using a mirror where it is difficult to see for any damage Pk iQ amp xt Ze Front brake hoses SSZ an N ei r D CO ae vn e wi ae Rear brake pipe boys S1M0154A B e CH ECKI NG SA07694G27 1 D SERVICE BRAKE SA07694G2701 1 Check the free play of brake pedal with a force of less than 10 N 1 kgf 2 Ib Brake pedal free play 1 3 mm 0 04 0 12 in Lock nut Brake booster operating rod Pedal play 1 3 mm 0 04 0 12 in Play at pin Ka GI0050A 2 If the free play is out of specifications above adjust the brake pedal as follows 1 Be sure engine is off No vacuum is applied to brake booster 2 There should be play between brake booster clevis and pin at brake pedal installing portion Depress brake pedal pad with a force of less than 10 N 1 kgf 2 Ib to a stroke of 1 to 3 mm 0 04 to 0 12 in 3 Depress the surface of brake pad by hand 4 If there is no free play between clevis pin and clevis turn brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0 3 mm 0 012 in Brake switch Brake booster opera
46. elow Static Checks Just After Vehicle Receipt Check point 1 Appearance check 1 Ifthe vehicle is covered with protective coating visually check the vehicle body for damage and dents If the protective coating has been removed visually check the body paints for small areas of damage or stains 2 Visually check the glass and light lenses for any damage and cracks or excessive gaps to the body sheet metal 3 Visually check the plated parts for any damage 2 Tire check 1 Check the tires for damage abnormal conditions and dents on the wheels 2 Check the tire air pressure 3 Fuse installation 1 If the vehicle is about to be delivered to the customer attach a room lamp fuse 4 Check the doors for lock unlock and open 1 Using the key check if the door can be locked and unlocked normally close operations 2 Open and close the all doors to see that there are no abnormal condi tions 5 Operation check of trunk lock release lever 1 Operate the trunk lock release lever to check that the trunk opens nor mally 6 Check the rear gate for lock unlock and open 1 Using the key check if the door can be locked and unlocked normally close operations 2 Open and close the doors to see that there are no abnormal condi tions 7 Operation check of fuel lid opener lock release 1 Operate the fuel lid opener to check that the fuel lid is unlocked nor lever mally 8 Operation check of child lock system 1 Check
47. enance Services C INSPECTION SA07685A10 1 SOHC MODEL SA07685A1001 1 Remove left and right timing belt covers 2 While cranking engine at least four rotations check timing belt back surface for cracks or dam age Replace faulty timing belt as needed 3 Measure timing belt width W If it is less than 27 mm 1 06 in check idlers tensioner water pump pulley and cam sprocket to determine idler align ment Squareness Replace worn timing belt GI0028A 4 Install left and right timing belt covers 2 DOHC MODEL SA07685A1002 1 Remove left and right timing belt covers 2 While cranking engine at least four rotations check timing belt back surface for cracks or dam age Replace faulty timing belt as needed 3 Measure timing belt width W If it is less than 30 mm 1 18 in check idlers tensioner water pump pulley and cam sprocket to determine idler align ment squareness Replace worn timing belt 4 Install left and right timing belt covers S1MO151A PM 13 VALVE CLEARANCE Periodic Maintenance Services 8 Valve Clearance sur A INSPECTION SA07083A10 For the inspection procedures of the valve clear ance lt Ref to ME SOHC 29 Valve Clearance gt or lt Ref to ME DOHC TURBO 28 Valve Clear ance gt PM 14 FUEL LINE Periodic Maintenance Services 9 Fuel Line SA07686 A INSPECTION sera The fuel line is located mostly internally so check pipes areas near pipes
48. ensions are installed 4 When no components are deformed adjust wheel arch height by replacing coil spring in the suspension whose wheel arch height is out of stan dard lt Ref to FS 6 Wheel Alignment gt and lt Ref to RS 7 Wheel Alignment gt PM 35 SUSPENSION Periodic Maintenance Services 4 WHEEL ALIGNMENT OF FRONT SUSPENSION SA07697A1004 1 Check alignment of front suspension to ensure that following items conform to standard values e Toe in e Camber angle e Caster angle e Steering angle lt Ref to FS 6 Wheel Alignment gt 2 When caster angle does not conform to stan dard value visually inspect following components and replace deformed parts e Suspension components Strut crossmember transverse link etc e Body parts to which suspensions are installed 3 When toe in and camber are out of standard value adjust them so that they conform to respec tive service standard 4 When right and left turning angles of tire are out of standard adjust to standard value 5 WHEEL ALIGNMENT OF REAR SUSPENSION SA07697A 1005 1 Check alignment of rear suspension to ensure that following items are within standard values e Toe in e Camber angle e Thrust angle lt Ref to RS 7 Wheel Alignment gt 2 When camber angle does not conform to stan dard value visually inspect parts listed below If deformation is observed replace damaged parts e Suspension components Strut assembly crossmember
49. ervices 25 Wheel Bearing svs A INSPECTION sera 1 FRONT WHEEL BEARING een NOTE Inspect the condition of front wheel bearing grease 1 Jack up the front of vehicle 2 While holding front wheel by hand swing it in and out to check bearing free play 3 Loosen wheel nuts and remove front wheel 4 If bearing free play exists in step 2 above attach a dial gauge to hub and measure axial dis placement in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in 5 Remove bolts and self locking nuts and extract transverse link from front crossmember 6 While lightly hammering spring pin which secures S F J to transmission spindle remove it 7 Extract S F J from transmission spindle lt Ref to DS 17 Front Axle gt 8 While supporting front drive shaft horizontally with one hand turn hub with the other to check for noise or binding If hub is noisy or binds disassemble front axle and check condition of oil seals bearing etc Inner oil seal Hub bolt t Snap ring RR Bearing Q Housing Outer oil seal GI0133 2 REAR WHEEL BEARING esu 1 Jack up the rear of vehicle 2 While holding rear wheel by hand swing it in and out to check bearing free play 3 Loosen wheel nuts and remove rear wheel 4 If bearing free play exists in step 2 above attach a dial gauge to hub COMPL and measure axial displacement in axial direction Service limit St
50. f water must be made strong occasionally by pressing the end of the hose NOTE Be sure to keep the hose at least 10 cm 3 9 in from the vehicle e Check the following areas e Front window and body framework mating portion e Door mating portions e Glass mating portions e Rear quarter window mating portions e Rear window and body framework mating portion e Around roof drips e H any dampness in the compartments is discov ered after the water has been applied carefully check all areas that may have possibly contributed to the leak 46 APPEARANCE CHECK 2 enen Check the vehicle body paints plated faces glass and lenses for any dirt or damage PI 11 PRE DELIVERY INSPECTION Pre delivery Inspection MEMO PI 12 PERIODIC MAINTENANCE SERVICES PM Page NNEN E SU EE H 3 Engine Ole 6 4 Engine Oil Eiter 8 5 Spark TEEN g Gi Drive E O hd 7 Gamshalt Drive Bel ana anni a an hd Celtes Eeer hd EN 15 10 Fuel UE 16 11 Ar Cleaner Elementi EE iF 12 e iTA E 18 12 GOOIEN ensure Hg LE 21 15 Clutch System aussen pd 16 Hill holder System nanne eneen eneen eeens eenen 24 17 Transmission Olle 25 18 Alfons eine 26 19 Front amp Rear Differential OU EE 21 Brake TEE Bi 22 Disc Brake Pads and DISCS nnee eneen eenen eneen eed 32 23 Brake Linings and DRUMS saar esra eendekker did 33 24 ROSIN SUN achat peas a acs eee eee ces cance E 35 25 Wheel BEAM serdar een een 37 26 Axle
51. hat each seat provides full functionality in sliding and reclining Check all available functions of the rear seat such as a trunk through center arm rest 23 SEAT BELT SA09719G5024 Pull out the seat belt and then release it Check that the belt webbing retracts smoothly 24 WHEEL ALIGNMENT eene Check the wheel alignments lt Ref to FS 6 Wheel Alignment gt and lt Ref to RS 7 Wheel Alignment gt PI 8 PRE DELIVERY INSPECTION 25 READ MEMORY AND TEST MODE CONNECTORS SA09719G5050 Turn the ignition switch to ON and check that the check engine light starts blinking If the light blinks return the ignition key to LOCK and disconnect the test mode connector Then turn the ignition key to ON again If the check engine light blinks at that time in spite of the disconnected test mode connector carry out an engine diagnosis With OBD model connector Green ur EN GI0095A Wi onnector Green OK ON GI0119A 26 STARTING CONDITION 7196502 Start the engine and check that the engine starts smoothly If any battery voltage problems are found recharge or replace the battery If any abnormal noises are observed immediately stop the engine and check and repair the necessary components 27 EXHAUST SYSTEM SA09719G5030 Listen to the exhaust noise to see if no abnormal noises are observed 28 INDICATOR LIGHT 510971985031 Check that all the indicator lights are off 29 CLOCK
52. he table in figure Engine oil capacity Non TURBO model Upper level 4 5 4 8 US qt 4 0 Imp qt Lower level 3 5 3 7 US qt 3 1 Imp qt Engine oil capacity TURBO model Upper level 5 0 5 3 US qt 4 4 Imp qt Lower level 4 0 4 2 US qt 3 5 Imp qt SAE Viscosity No and Applicable Temperature CC 30 20 a 0 15 30 40 CF 22 4 5 32 59 86 104 10W 30 10W 40 5W 30 PREFERRED GI0015A The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed NOTE e When replenishing oil it does not matter if the oil to be added is a different brand from that in the engine however use oil having the API classifica tion and SAE viscosity No designated by SUBARU e 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 20W 50 6 Close engine oil filler cap 7 Start engine and warm it up for a time 8 After engine stops recheck the oil level If necessary add engine oil up to upper level on level gauge Oil level gauge 077777 Notch mark ch Nu Engine oil filler cap o Upper level 2 About 1 0 1 1 US qt 0 9 Imp qt Lower level GI0016A Z oL PM 6 ENGINE OIL Periodic Maintenance Services
53. icle is balanced before raising it Support locations Pantograph jack Lift Safety stand S1M0137A NT 3 NOTE CEA Support position Hr Kee ee Ei E lt DW Nice Ne zee AN TS SS I EA I Ef Ze N S1MO138A Rear LY UN BILE Sass Ci CS gt NT Aer amp SH ZI PSs g O De we g Da WS IS S1MO139A NT 4 NOTE Note 6 TIE DOWNS SA03676A 1506 Tie downs are used when transporting vehicles and when using the chassis dynamo Attach tie downs only to the specified points on the vehicle Front ES Tie down range S1M0142A Hooks for towing and tie down S1M0140A Rear Hook for towing and tie down Hook for tie down S1M0141A SE EE LS LXI 7 TOWI NG SA03676A1507 Avoid towing vehicles except when the vehicle cannot be driven For vehicles with AWD AT or VTD use a loader instead of towing When towing other vehicles to prevent excessive weight from damaging the hook or vehicle e Do not tow other vehicles with a front towing hook e Make sure the vehicle towing is heavier that the vehicle being towed 8 TRAI N l NG SA03676A1508 For information about training contact a dealer or agent 9 GENERAL SCAN TOOL SA03676A1509 Using
54. il filter Replace more frequently Replace more frequently Replace more frequently Replace more frequently Replace more frequently Replace more frequently Fuel line Transmission oil 6 months 12 500 km 7 500 miles Replace more frequently ATF Replace more frequently Front amp rear dif ferential oil Replace more frequently Brake line 6 months 12 500 km 7 500 miles Brake fluid 12 months 25 000 km 15 000 miles Brake pads 6 months 12 500 km 7 500 miles Brake linings and drums Parking brake Suspension Axle boots amp joints 6 months 12 500 km 7 500 miles 6 months 12 500 km 7 500 miles 6 months 12 500 km 7 500 miles 6 months 12 500 km 7 500 miles Steering system Power steering 6 months 12 500 km 7 500 miles PM 5 ENGINE OIL Periodic Maintenance Services 3 Engine Oil SA07077 A REPLACEMENT SA07077A20 1 Drain engine oil by loosening engine oil drain plug GI0012A 2 Open engine oil filler cap for quick draining of the engine oil 3 Replace drain plug gasket 4 Tighten engine oil drain plug after draining engine oil Tightening torque 44 N m 4 5 kgf m 33 ft Ib 5 Fill engine oil through filler pipe up to upper point on level gauge Make sure that vehicle is placed level when checking oil level Use engine oil of proper quality and viscosity selected in accor dance with t
55. ilize 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 ENGINE DIAGNOSTICS EN SOHCw oOBD FUEL INJECTION FUEL SYSTEMS FU DOHC TURBO EMISSION CONTROL AUX EMISSION CONTROL DEVICES EC DOHC TURBO INTAKE INDUCTION IN DOHC TURBO MECHANICAL ME DOHC TURBO EXHAUST EX DOHC TURBO IGNITION ei le s lem ge 1 70 ENGINE DIAGNOSTICS EN DOHC TURBO 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 G8050GE3 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS AUTOMATIC TRANSMISSION MANUAL TRANSMISSION AND DIFFERENTIAL CLUTCH SYSTEM 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
56. int e O2 sensor e Bolts etc MT main shaft Clutch master cylinder push rod Recommended SUBARU CRC FX clutch grease Slicolube G 40M Item number 004301003 000040901 004404003 None Alternative e Steering shaft bear ing e Gear shift bush SUNLIGHT2 003602010 Steering gear box Valiant grease M 2 003608001 Disc brake Drum brake e Brake pad e Brake shoe Front axle SFJ Front BJ Rear axle BJ Rear axle EBJ Turbo model Niglube RX 2 Molykote No 7439 Molykote AS 880N SSG 6003 NTG 2218 Molykote No 2 NTG 2218 003606000 or 725191040 72519460 26298AC000 28093TA000 28093AA000 723223010 28093AA000 Rear axle DOJ e Control cable e Throttle linkage e Water pump e Door latch e Door striker VU 3A702 Slicolube G 30M RM 5 23223GA050 004404002 RECOMMENDED MATERIALS Recommended Materials 8 ADHESIVES SA05678G2210 Use the adhesives shown in the table below or equivalent Alternative Adhesive Adhesive Application point Windshield and body Recommended Essex Chemical Crop s Ure thane E Sunstar 580 Weatherstrip rubber parts Cemedine 5430L 3M s EC 1770 EC 1368 Soft vinyl Cemedine 540 3M s EC 776 EC 847 or EC 1022 Spray type Momentary sealant 9 SEAL MATERIAL s4ose736220s Use seal material shown in the table below or equivalent Seal material Application point
57. mally 9 Window washer heck that the window washer system operates normally 10 Wiper 1 Check that the wiper system operates normally 11 Power window operation check 1 Check the power window for correct operations Dynamic Test with the Vehicle Running 7 1 7 7 7 C C C C C C C C Check point heck that the foot brake operates normally heck that the parking brake operates normally heck the AT shift patterns are correct 4 Heater amp ventilation heck that the heater amp ventilation system operates normally 5 Air conditioner heck that the air conditioner operates normally 6 Cruise control heck that the cruise control system operates normally Checks after Dynamic Test 1 Brake test 2 Parking brake 3 AT shift control 1 1 1 1 1 1 Step Check point 1 ATF level heck that the ATF level is normal 2 Power steering fluid level heck that the power steering fluid level is normal 3 Fluid leak check heck for fluid oil leaks 4 Water leak check pray the vehicle with water and check for water leaks 5 Appearance check 2 emove the protective coating if any heck the body paints for damage and smears heck the plated parts for damage and rust PLA PRE DELIVERY INSPECTION Pre delivery Inspection 1 APPEARANCE CHECK seen e f the vehicle is covered with protecti
58. mix two different kinds or makes of fluid Fluid Recommended Alternative Remarks Automatic transmission fluid DEXRON III Power steering fluid DEXRON Ill Brake fluid FMVSS No 116 DOT3 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 RECOMMENDED MATERIALS Recommended Materials The table below shows the ratio of coolant to distilled water Coolant Specifications Specification gravity SUBARU coolant to water ratio Volume Lowest antici pated atmo spheric tem perature at 40 C Freezing point 104 F at 50 C 122 F Above 30 C 22 F Above 15 C 5 F 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 Recommended Item number Alternative Refrigerant HFC134a None Compressor oil 7 GREASE SA05678G2207 ZXL200PG Use the grease and supplementary lubricants shown in the table below Grease Supplementary lubricants Grease Application po
59. mp Sunroof SRS airbag Driver amp Passenger Cold weather pack 2 6 5 7 SRS airbag Side Rear kg Ib 4 4 9 7 Total kg Ib SPC 6 7 0 15 4 PRECAUTION PRECAUTION Precaution 1 Precaution ser A PRECAUTION siers Please clearly understand and adhere to the fol lowing general precautions They must be strictly followed to avoid minor or serious injury to the per son doing the work or people in the area 1 ABS SA04677F5901 Handle the ABS as a total system Do not disas semble or attempt to repair individual parts Doing so could prevent the ABS system from operating when needed or cause it to operate incorrectly and result in injury 2 BRAKE FLUID SA04677F5902 If brake fluid gets in your eyes or on your skin do the following e Wash out your eyes and seek immediate medi cal attention e Wash your skin with soap and then rinse thor oughly with water 3 ELECTRIC FAN SA04677F5903 The electric fan may rotate without warning even when the engine is not on Do not place your hand cloth tools or other items near the fan at any time 4 ROAD TESTS SA04677F5904 Always conduct road tests in accordance with traf fic rules and regulations to avoid bodily injury and interrupting traffic 5 AIRBAG SA04677F5905 To prevent bodily injury from unexpected deploy ment of airbags and unnecessary maintenance follow the instructions in this manu
60. nge or the like 1 Check at temperature 20 68 F on res ervoir surface of oil pump read the fluid level on the COLD side 2 Check at temperature 80 C 176 F on res ervoir surface of oil pump read the fluid level on the HOT side Non turbo model H4M1007 FD HOT may GOLD MAX SC ae a a L V 1 a du H 1 4 a Zo e 1 il Lh F Une lial l F h WE m ch d Fi il i IG Ge hr s ws d B N fi i p P d fy Al t Wee hs x Z ary i NT Al Ki DN kf F d e ah B4M1674A 44 FLUID LEAK CHECK see Check the entire areas of the vehicle for any trace of coolant oil fluid leaks PI 10 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 e Before performing the water leakage test remove anything that may obstruct the operation or which must be kept dry e Close all of the windows completely and then close all of the doors tightly Close the hood and trunk lid before starting the test e Connect a hose to a tap and spray water on the vehicle The rate of water discharge must be approx 20 to 25 liters 5 3 to 6 6 US gal 4 4 to 5 5 Imp gal per minute When spraying water on areas adjacent to the floor and wheel house increase the pressure When directing water on areas other than the floor portion and wheel house decrease the pressure But the force o
61. odel 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 Meaning Details Series Forester Body style F Wagon Engine displacement Drive system Suspension system 5 2 0 LAWD 9 2 5 LAWD Minor change 2001MY Destination Transmission fuel feed system The engine and transmission type are as follows e Engine EJ20DAXBBB Meaning Right hand drive for general market Left hand drive for general market K L Y For United States Canada 2 BASE 3 HUNTER Ver 4 NA SPORT 5 TYPES E DOHC MPI 4 speed AT P DOHC MPI Turbo 4 speed AT DOHC MPI Turbo center differential AWD SOHC MPI center differential AWD R SOHC MPI 4 speed AT Details Engine type EJ 4 cylinders Displacement 20 2 0 L 25 2 5L Fuel feed system 1 D MPI SOHC A 2 D MPI SOHC B 4 MPI DOHC 5 MPI Turbo Detailed specifications Used when ordering parts See the parts catalog for details Transmission W AWD MT X AWD AT Detailed specifications Used when ordering parts See the parts catalog for details ID 5 Identification IDENTIFICATION e Transmission TZ1A3ZS3AA Meaning Details Transmission T Transmission Transmission type Y Full time AWD MT center differential Z
62. of parts during repair work is needed be sure to use SUBARU genu ine parts AUTOMATIC TRANSMISSION DIAGNOSTICS 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 G8050GE4 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS 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 TRANSFER CASE DRIVE SHAFT SYSTEM ABS BRAKE PARKING BRAKE POWER ASSISTED SYSTEM POWER STEERING ABS DIAGNOSTICS 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 G8050GE5 2001 FORESTER SERVICE M
63. om coolant flow tank filler port up to the brim of port and install cap then pour coolant into reserve tank up to FULL level 2 Run engine for about 15 minutes not exceeding 2 000 rpm Run engine until radiator becomes hot in order to purge air trapped in cooling system 3 Stop engine and wait until coolant tempera ture lowers below 50 C 122 F or 60 C 140 F Open coolant flow tank cap and add coolant up to the brim of the port 4 Wait until coolant temperature lowers fur ther below 30 C 86 F then pour into reserve tank up to the FULL level 5 Run the vehicle until the coolant tempera ture rises to 80 C 176 F and check the level in the coolant flow tank add coolant up to the FULL level Coolant capacity fill up to FULL level MT model Approx 6 4 6 8 US qt 5 6 Imp qt AT model Approx 6 3 6 7 US qt 5 5 Imp qt PM 19 COOLANT Periodic Maintenance Services 2 RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEM PE RATU R E SA07689A2002 The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram Measuring the temperature and specific gravity of the coolant will provide this information Example If the coolant temperature is 25 C 77 F and its specific gravity is 1 054 the concentration is 35 point A the safe operating temperature is 14 C 7 F point B and the freezing temperature is 20 C 4
64. operating cylinder and check if the fluid level in the clutch reservoir tank rises or not C3 Release lever NJ Non TURBO model Operating cylinder Gl0128 TURBO model LL IN N NA Release lever VS cylinder IA S1M0159A 2 If the fluid level rises pedal free play is correct 3 If the fluid level does not rise or the push rod cannot be retracted adjust the clutch pedal lt Ref to CL 37 Clutch Pedal gt 4 Inspect the underside of master cylinder clutch damper and operating cylinder for clutch system hoses piping and their couplings for fluid leaks If fluid leaks are found correct them by retighten ing their fitting bolt and or replacing their parts 5 Check the fluid level using the scale on the outside of the clutch master cylinder tank A If the level is below MIN B add clutch fluid to bring it up to MAX C Recommended clutch fluid FMVSS No 116 fresh DOT3 or DOT4 brake fluid PM 22 CLUTCH SYSTEM Periodic Maintenance Services NOTE e Avoid mixing different brakes of brake fluid to prevent degradation of the fluid e Be careful not to allow dirt or dust to get into the reservoir tank PM 23 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
65. osis terminal is connected to the ground terminal 4 When the warning light indicates a trouble code check the airbag system in accordance with the troubleshooting procedure lt Ref to AB 2 Basic Diagnostic Procedure gt PM 42
66. r rectly attained Selector lever gate pattern GI Pp Ba Lo R pI SH N ec gt p T ES 2 ES amp 1 S RHD LHD GIO113A Selector Gear Position Position Yes Yes Yes Yes Yes 39 HEATER amp VENTILATION seat Operate the heater and ventilation system to check for normal airflow and heating capacity 40 AIR CONDITIONER neess Operate the air conditioner Check that the A C compressor operates normally and enough cooling is provided 41 CRUISE CONTROL SA09719G5044 Operate the cruise control system Check that the system is activated and deactivated correctly 42 ATF LEVEL SA09719G5045 Check that the ATF level is normal If insufficient check that no leaks are found Then add the nec essary amount of the specified ATF Upper level Lower level GI0098A 43 POWER STEERING FLUID LEVEL SA09719G5046 1 Check power steering fluid for deterioration or contamination If the fluid is highly deteriorated or contaminated drain it and refill with new fluid 2 Check joints and units for oil leakage If any oil leaks are found repair or replace the applicable part 3 Inspect fluid level on flat and level surface with engine OFF by indicator of reservoir tank If the level is at lower point or below add fluid to keep the level in the specified range of the indica tor If at upper point or above drain fluid by using a syri
67. r ATF leaked For the replacement procedures of the ATF filter lt Ref to AT 46 ATF Filter gt PM 26 FRONT amp REAR DIFFERENTIAL OIL 19 Front amp Rear Differential Oil SA07693 A REPLACEMENT SA07693A20 1 FRONT DIFFERENTIAL MANUAL TRANSMISSION SA07693A2001 For M T vehicle manual transmission oil works as differential oil to lubricate differential Refer to Transmission Oil lt Ref to PM MANUAL TRANSMISSION REPLACEMENT Transmission Oil gt 2 FRONT DIFFERENTIAL AUTOMATIC TRANSMISSION SA07693A2002 1 Drain differential 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 GI0045 2 Reinstall drain plug after draining differential gear oil and tighten it to the specified torque Tightening torque 44 N m 4 5 kgf m 32 5 ft Ib NOTE e Be sure to place a gasket between the transmis sion case and drain plug e Replace the gasket with a new one e Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands Periodic Maintenance Services 3 Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge Differential gear oil capacity 1 1 1 34 1 2 1 4 US qt 1 0 1 1 Imp qt tr Lower level Upper level GI0046A 3 REAR DIFFERENTIAL 517634203 1 Drain oil by removing drain plug
68. raight ahead position within 0 05 mm 0 0020 in 5 Remove the DOJ of rear drive shaft from rear differential lt Ref to DS 38 Rear Drive Shaft gt 6 While supporting rear drive shaft horizontally with one hand turn hub COMPL with the other to check for noise or binding If hub COMPL is noisy or binds disassemble rear axle and check condition of oil seals bearings etc Inner oil seal Rear housing t a Tone wheel S With ABS only Ke 4 Hub bolt g i Socket bolt Bearing 2 With ABS only Snap ring EN DENN Outer oil seal AN ER I N So GI0134 PM 37 AXLE BOOTS amp JOINTS Periodic Maintenance Services 26 Axle Boots amp JOINS s A INSPECTION SA07699A10 1 FRONT AND REAR AXLE BOOTS zeman Inspect front axle boots A and rear axle boots B for deformation damage or failure If faulty replace them with new ones lt Ref to DS 32 Front Drive Shaft gt and lt Ref to DS 38 Rear Drive Shaft gt 7 MAIN N GI0135 2 PROPELLER SHAFT ssozsa9a1000 Inspect propeller shaft for damage or failure If faulty replace with new one lt Ref to DS 14 Pro peller Shaft gt PM 38 STEERING SYSTEM POWER STEERING 27 Steering System Power Steering sor A INSPECTION SA07701A10 1 STEERING WHEEL uo 1 Set steering wheel in a straight ahead position and check wheel spokes to make sure they are correctly set in their specified positions 2 Lightly
69. rify that the fuel lid opens normally Check that the filler cap is securely closed 8 CHECK THE OPERATION OF CHILD SAFETY LOCKS SA09719G5052 1 Set the child safety lock on both rear doors to the lock positions 2 Close the rear doors completely 3 Check that the lock levers of the rear doors are in the unlock positions Then pull the inside door handles of the rear doors to ensure that the doors will not open 4 Next pull the outside door handles of the rear doors to ensure that the doors will open 5 Repeat the above steps two or three times S1M0157A PI 6 9 ACCESSORY CHECK SA09719G5008 Check that the following accessories are provided in the luggage compartment or cargo area e Owner s manual Warranty booklet Service booklet Spare key Jack Tool set Spare tire S1M0143A 10 OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM SA09719G5009 Unlatch and open the hood while checking that no abnormal conditions are found Then support the hood with the hood stay LT We A O GI0082A a S1M0144A PRE DELIVERY INSPECTION Pre delivery Inspection 11 CONNECTION OF AIR CONDITIONER HARNESS SA09719G5011 A vehicle just delivered has its air conditioner har ness disconnected to protect the air conditioner compressor Connect the harness as shown in the figure GI0085 12 BATTERY SA09719G5012
70. rum is streaked correct the surface with emery cloth 200 or more If it is unevenly worn tapered or the out side surface of brake drum is damaged correct or replace it Brake drum inner diameter Standard value 228 6 mm 9 000 in Service limit 230 6 mm 9 079 in If deformation or wear of back plate shoe etc is noticeable replace the affected parts Measuring inside diameter GIO060A 2 PARKING BRAKE REAR DISC BRAKE SA07696A 1002 Inspect brake linings and drums of both sides of the rear brake at the same time by removing brake drums 1 Inspect brake shoes for damage or deformation and check brake linings for wear NOTE Always replace both primary and secondary brake shoes for the left and right wheels at the same time Brake lining thickness excluding back metal Standard value 3 2 mm 0 126 in Wear limit 1 5 mm 0 059 in N gt Brake shoe SF Secondary S1M0158A Primary PM 33 BRAKE LININGS AND DRUMS Periodic Maintenance Services 2 Check brake drum for wear dents or other damage If the inside surface of brake drum is streaked correct the surface with emery cloth 200 or more If it is unevenly worn tapered or the outside surface of brake drum is damaged correct or replace it Brake drum inside diameter Standard value 170 mm 6 69 in Wear limit 171 mm 6 73 in Disc brake Disc Measuring inside diameter
71. s 2 Remove the clip B above the air cleaner case H2M2947A 3 Remove air cleaner 4 Install in the reverse order of removal CAUTION Fasten with a clip after inserting the lower tab of the case Periodic Maintenance Services 2 TURBO MODEL SA07687A2002 GI0126 1 Remove the clip B above the air cleaner case 2 Remove air cleaner 3 Install in the reverse order of removal CAUTION Before installing air cleaner upper cover align holes with protruding portion of air cleaner lower case then secure upper cover to lower case EN0906 PM 17 COOLING SYSTEM Periodic Maintenance Services 12 Cooling System su A INSPECTION su 1 Check radiator for leakage filling it with coolant and attach radiator cap tester A to the filler neck Then apply a pressure of 157 kPa 1 6 kg cm 23 psi and check the following points e Each portion of radiator for leakage e Hose joints and other connections for leakage CAUTION e When attaching or detaching tester and when operating tester use special care not to deform radiator filler neck Non TURBO model S1M0153A e When performing this check be sure to keep the engine stationary and fill radiator with cool ant e Wipe off check points before applying pres sure e Use care not to spill coolant when detaching tester from radiator 2 Check the radiator cap v
72. servoir If the amount is insufficient check that no leaks are found Then add the necessary amount of coolant with the specified concentration 18 CLUTCH FLUID SA09719G5018 Check the clutch fluid amount If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified fluid GI0090A 19 WINDOW WASHER FLUID scene Check the window washer fluid amount If the amount is insufficient check that no leaks are found Then add the necessary amount of washer fluid commercially available 20 HOOD LATCH CHECK SA09719G5020 Retract the hood stay and close the hood Check that the hood is securely latched 21 KEYLESS ENTRY SYSTEM ses Check the keyless entry system operations as fol lows e Remove the key from the ignition switch and close all the doors including rear gate wagon e Press the LOCK button on the transmitter momentarily once and check if all the doors are locked and the hazard light flashes ones B5M1182 e Press the OPEN button on the transmitter momentarily once and check if the driver s door is unlocked the hazard light flashes twice and the dome light illuminates e Close all doors and rear gate press the LOCK button of the transmitter Press the OPEN button of the transmitter and wait for 30 seconds Check that all doors and the rear gate are automatically locked again 22 D S EAT SA09719G5023 Check t
73. the imme diately preceding two steps remove and inspect ball joint If free play exceeds standard replace ball joint lt Ref to FS 17 Front Ball Joint gt Transverse link Ball joint GI0064A Transverse link Ball joint GI0065A 5 Damage of dust seal Visually inspect ball joint dust seal If it is damaged remove transverse link lt Ref to FS 14 Front Transverse Link gt And measure free play of ball joint lt Ref to FS 17 Front Ball Joint gt 1 When looseness exceeds standard value replace ball joint 2 If the dust seal is damaged replace with the new ball joint NOTE When transverse link ball joint has been removed or replaced check toe in of front wheel If front wheel toe in is not at specified value adjust toe in lt Ref to FS 6 Wheel Alignment gt GI0066A 2 TRANSVERSE LINK S REAR BUSHING SA07697A1002 Check oil leaks at around liquid filled bushing If oil leaks replace bushing D gas lt 17 z GI0067A 3 WHEEL ARCH HEIGHT saors7a100s 1 Unload cargoes and set vehicle in curb weight condition 2 Then check wheel arch height of front and rear suspensions to ensure that they are within speci fied values 3 When wheel arch height is out of standard visually inspect following components and replace deformed parts e Suspension components Front strut assembly and rear strut assembly e Body parts to which susp
74. ting rod Play at pin Pedal play 1 3 mm 0 04 0 12 in GI0051A PM 29 BRAKE LINE Periodic Maintenance Services 3 Check the pedal stroke While the engine is idling depress the brake pedal with a 490 N 50 kgf 110 Ib load and measure the distance between the brake pedal and steering wheel With the brake pedal released measure the distance between the pedal and steering wheel again The difference between the two measure ments must be less than 95 mm 3 74 in If the distance is more than specified there is a possibil ity air is in the inside of the hydraulic unit Brake pedal reserve distance A more than 95 mm 3 74 in 490 N 50 kof 110 Ib lH L2 A Toe board GI0052A 4 Check to see if air is in the hydraulic brake line by the feel of pedal operation If air appears to exist in the line bleed it from the system 5 Check for even operation of all brakes using a brake tester or by driving the vehicle for a short distance on a straight road 2 BRAKE SERVO SYSTEM eneen 1 With the engine off depress the brake pedal several times applying the same pedal force Make sure the travel distance should not change 2 With the brake pedal depressed start the engine Make sure the pedal should move slightly toward the floor 3 With the brake pedal depressed stop the engine and keep the pedal depressed for 30 sec onds Make sure the pedal height should not change
75. tration Be 5 5 of coolant 5 3 2 2 6 o 65 EME S 2 1 1 8 Bai g 1 E 1 1 1 8 8 0 5 10 20 30 40 50 gt Concentration of coolant in the vehicle cooling system 5 O Concentration of coolant in vehicle and quantity to be drained GI0038A PM 20 IDLE MIXTURE Periodic Maintenance Services 14 Idle Mixture A INSPECTION AND ADJUSTMENT SA07734G26 1 IDLE MIXTURE 477346250 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 for AT 2 Warm up engine sufficiently until cooling fan starts to operate 3 Measure the idle mixture with the CO meter Engine idle speed co 700 100 rpm 1 0 0 5 4 If out of specification adjust the idle mixture using CO adjusting screw of mass air flow sensor 5 After adjusting the CO value check and adjust increment coefficient of CO resistor by using Select Monitor 1 Select Current data display amp Save on the select monitor 2 If out of specified data adjust the increment coefficient of CO resistor while rotating CO adjusting screw Specified data 0 28 4 22 V kE Se gt GI0114A NOTE If driving the vehicle on out of specified data the trouble code 49 is indicated in many case PM 21 CLUTCH SYSTEM Periodic Maintenance Services 15 Clutch System sun A INS
76. turn steering wheel to the left and right to determine the point where front wheels start to move Measure the distance of the movement of steering wheel at the outer periphery of wheel Steering wheel free play 0 17 mm 0 0 67 in GI0074A Move steering wheel vertically toward the shaft to ascertain if there is play in the direction Maximum permissible play 0 5 mm 0 020 in 3 Drive vehicle and check the following items dur ing operation 1 Steering force The effort required for steering should be smooth and even at all points and should not vary 2 Pull to one side Steering wheel should not be pulled to either side while driving on a level surface 3 Wheel runout Steering wheel should not show any sign of runout 4 Return factor Steering wheel should return to its original posi tion after it has been turned and then released Periodic Maintenance Services 2 STEERING SHAFT JOINT ams 1 When steering wheel free play is excessive disconnect universal joint of steering shaft and check it for any play and yawing torque at the point of the crossing direction Also inspect for any damage to sealing or worn serrations If the joint is loose retighten the mounting bolts to the specified torque Tightening torque 24 N m 2 4 kgf m 17 4 ft lb G10075A 3 GEARBOX SA07701A1003 1 With wheels placed on a level surface
77. ve coating visually check the vehicle body for damage and dents e f there is no protective coating check the body paints for small areas of damage or stains and repair as necessary e Check the window glass door glass and lights for any cracks or damage and repair or replace the parts as necessary e Check the plated parts such as the grilles and door knobs for damage or loss of gloss and repair or replace the parts as necessary 2 TIRE CHECK SA09719G5002 e Check the tire outer faces for any damage e Check the tire air pressure by referring to the following table Tire inflation pressure kPa kg cm psi Tire size P205 70R15 95S 205 70R15 95H TURBO 205 70R15 95Q SNOW P215 60R16 94H 215 60R16 95V 215 60R16 95Q 200 250 SNOW 2 0 29 2 5 36 Australia model NOTE e After inspecting and adjusting the tire pressure be sure to put the valve cap back e When towing adjust the tire inflation pressures as follows Front 200 kPa 2 0 kg cm 29 psi Rear 280 kPa 2 8 kg cm 41 psi 3 FUSE INSTALLATION eneen A vehicle just delivered has no fuses for the room lamp circuit to prevent battery discharge Attach a 15 A fuse as shown in the figure IN GE LU eat mi Ee A GI0084A 4 CHE
78. ves of gearbox and the rod 2 Clips are fitted outside of A and B positions of boot 3 Boot does not have crack and hole NOTE Rotate B position of gearbox boot against twist of it produced by adjustment of toe in etc Apply grease GI0023A 10 FITTING BOLTS AND NUTS eum Inspect fitting bolts and nuts of oil pump and bracket for looseness and retighten them if neces sary Inspect and or retighten them when engine is cold PM 41 SUPPLEMENTAL RESTRAINT SYSTEM Periodic Maintenance Services 28 Supplemental Restraint System s A INSPECTION surxo Check the airbag system in accordance with the result of the self diagnosis lt Ref to AB 2 Basic Diagnos tic Procedure gt 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 AIRBAG warning light be AIR BAG C gt Q O O S1M0160A 2 Turn the ignition switch ON and connect the airbag diagnosis terminal of the service connector located below lower cover to the ground terminal 3 The warning light blinks to indicate a trouble code a fault is identified When the airbag system is in good order no trouble codes are stored in the memory the warning light blinks on and off at 0 6 second intervals as long as the diagn
79. y 100 000 km 60 000 tries miles Use in others Inspect every 160 000 km 100 000 miles Fuel line Fuel filter Air cleaner element Cooling system Coolant Idle mixture For models without catalyst con verter Clutch system Hill holder system Transmission oil ATF Front amp rear differ ential oil Brake line Brake fluid Disc brake pads amp discs Brake linings and drums Parking brake EEK TE DE EEE 23 Suspension TE PM 3 SCHEDULE Periodic Maintenance Services Maintenance Interval Number of months or km miles whichever occurs first Months Remarks x 1 000 km x 1 000 miles Wheel bearing Axle boots amp joints Steering system Power steering Symbols used R Replace I Inspection R or 1 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 2 ATF filter is maintenance free part ATF filter needs replacement when it has physically damaged or ATF leaked PM 4 SCHEDULE B MAINTENANCE SCHEDULE 2 en Repeat short distance drive Repeat rough muddy road drive Extremely cold weather area Periodic Maintenance Services Salt or other corrosive used or coastal area High humidity or mountain area Repeat tow ing trailer Engine oil Engine o

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