Subaru 2001 Forester User manual

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.
2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G8050GE6

BODY STRUCTURE BS
Page
1. General Description.....................................................................................2
2. Datum Points...............................................................................................3
3. Datum Dimensions....................................................................................15

1. General Description S906001
A: PREPARATION TOOL S906001A17
TOOL NAME REMARKS
Tram tracking gauge Used for measuring dimen-
sion.
Tape measure Used for measuring dimen-
sion
BS-2
GENERAL DESCRIPTION
Body Structure

2. Datum Points S906540
A: LOCATION S906540A13
NOTE:
쐌Datum points are specified for body repair.
쐌Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment
accuracy.
쐌Both right and left reference points are symmetrical.
BS-3
DATUM POINTS Body Structure

1. ROOM SECTION S906540A1301
S5M0073B
(1) Radiator panel (UPR) repair bolt
hole M8 (Right)
(2) Radiator panel (UPR) repair bolt
hole M8 (Left)
(3) Fender attaching bolt hole M6
(Symmetrical)
(4) Repair locator 8 mm (0.31 in)
dia. (Symmetrical)
(5) Radiator panel side gauge hole
24 mm (0.94 in) dia. (Symmetri-
cal)
(6) Front bumper mounting hole 14
×16 mm (0.55 ×0.63 in) dia.
(Symmetrical)
(7) Front crossmember attaching
bolt hole 12.4 mm (0.488 in) dia.
(Symmetrical)
(8) Fender attaching bolt hole M6
(Symmetrical)
(9) Front strut mounting hole 9.5
mm (0.374 in) dia. (Symmetrical)
(10) Hood hinge attaching bolt hole
M8 (Symmetrical)
(11) Cowl panel mounting hole 6 mm
(0.24 in) dia. (Symmetrical)
(12) Roof inner trim attaching bolt
hole 8 mm (0.31 in) dia.
(13) Fender attaching bolt hole M6
(Symmetrical)
(14) Front pillar gauge hole 20 mm
(0.79 in) dia. (Symmetrical)
(15) Wax coat hole 20 mm (0.79 in)
dia. (Symmetrical)
(16) Retainer attaching square hole 7
mm (0.28 in) (Symmetrical)
(17) Sun visor attaching hole 17 mm
(0.67 in) dia. (Symmetrical)
(18) Retainer attaching square hole 7
mm (0.28 in) (Symmetrical)
(19) Retainer attaching square hole 7
mm (0.28 in) (Symmetrical)
(20) Center pillar gauge hole 12 mm
(0.47 in) dia. (Symmetrical)
(21) Belt anchor attaching bolt hole
11.1 mm (7/16 in) dia. (Sym-
metrical)
(22) Wax coat hole, 20 mm (0.79 in)
dia. (Symmetrical)
(23) Rear door switch attaching hole
20 mm (0.79 in) dia. (Symmetri-
cal)
(24) Retainer attaching square hole 7
mm (0.28 in) (Symmetrical)
(25) Spare tire attaching bolt hole M8
(26) Air draw hole 7 mm (0.28 in) dia.
(Symmetrical)
(60) Fender attaching bolt hole M6
(Symmetrical)
(64) Door switch attaching hole 13.5
mm (0.531 in) dia. (Symmetrical)
(67) Front glass attaching hole Right
6.5 mm (0.256 in) dia. Left 6.5 ×
10 mm (0.256 ×0.39 in) dia.
BS-4
DATUM POINTS
Body Structure

2. REAR SECTION S906540A1302
S5M0074A
(27) Rear pillar (Inner) harness and
hose clip attaching hole 7 mm
(0.28 in) dia. (Symmetrical)
(34) Rear skirt gauge hole 20 mm
(0.79 in) dia. (Symmetrical)
(36) Rear quarter bumper side gauge
hole 20 mm (0.79 in) dia. (Left)
(37) Rear quarter bumper side gauge
hole 20 mm (0.79 in) dia. (Right)
(38) Instrument panel attaching
square hole 22 ×34.5 mm (0.87
×1.358 in) (Right)
(39) Steering support beam attaching
bolt hole M8 (Symmetrical)
(40) Front pillar (Inner) gauge hole 10
mm (0.39 in) dia. (Symmetrical)
(41) Floor mat attaching clip hole 8
mm (0.31 in) dia. (Symmetrical)
(42) Rear quarter glass attaching
hole 8 ×15 mm (0.31 ×0.59 in)
dia. (Symmetrical)
(43) Pad attaching square hole 9 mm
(0.35 in) dia. (Symmetrical)
(44) Rear quarter glass attaching
hole 8 mm (0.31 in) dia. (Sym-
metrical)
(45) Rear locator hollow 4 mm (0.16
in) dia.
(46) Rear strut mounting hole 10 mm
(0.39 in) dia. (Symmetrical)
(47) Rear gate stay attaching bolt
hole M8 (Symmetrical)
(48) Inner trim clip attaching hole 8 ×
20 mm (0.31 ×0.79 in) dia.
(Symmetrical)
(49) Rear combination light mounting
hole 8 mm (0.31 in) dia. (Sym-
metrical)
(61) Side rail (Inner) gauge hole 10
mm (0.39 in) dia. (Symmetrical)
(65) Repair location hole 12 mm
(0.47 in) dia. (Symmetrical)
(70) Buffer attaching hole M6 (Sym-
metrical)
(71) Bumper face attaching square
hole 8 ×9 mm (0.31 ×0.35 in)
(72) Bumper face attaching square
hole 8 ×9 mm (0.31 ×0.35 in)
(Symmetrical)
(73) Head console bracket gauge
hole 8 mm (0.31 in) dia.
(74) Inner system carrier attaching
bolt hole 8 mm (0.31 in) (Sym-
metrical)
(75) Inner system carrier attaching
bolt hole 8 mm (0.31 in) (Sym-
metrical)
(76) Head console bracket gauge
hole 8 mm (0.31 in) dia.
BS-5
DATUM POINTS Body Structure

3. UNDERBODY SECTION S906540A1303
S5M0075A
(50) Radiator panel (LWR) frame
gauge hole 15 mm (0.59 in) dia.
(Symmetrical)
(51) Front side frame gauge hole 20
mm (0.79 in) dia. (Symmetrical)
(52) Front crossmember attaching
hole 12.4 mm (0.488 in) dia.
(Symmetrical)
(53) Front suspension attaching bolt
hole M14
(54) Side frame gauge hole 20 mm
(0.79 in) dia. (Symmetrical)
(55) Repair location hole 12 mm
(0.47 in) dia. (Symmetrical)
(56) Side frame gauge hole 15 mm
(0.59 in) dia. (Symmetrical)
(57) Rear differential attaching bolt
hole M12 (Symmetrical)
(58) Rear suspension attaching bolt
hole M12 (Symmetrical)
(59) Rear side frame gauge hole 15
mm (0.59 in) dia. (Symmetrical)
BS-6
DATUM POINTS
Body Structure

S5M0076A S5M0077A
S5M0078A S5M0079A
S5M0080A S5M0081A
S5M0082A S5M0083B
BS-7
DATUM POINTS Body Structure

S5M0084A
S5M0085A
S5M0086A
S5M0087A
S5M0088A S5M0089A
S5M0090A S5M0091A
BS-8
DATUM POINTS
Body Structure

S5M0092A S5M0093A
S5M0094A S5M0095A
S5M0096A S5M0097A
S5M0098A S5M0099A
BS-9
DATUM POINTS Body Structure

S5M0100A S5M0101A
S5M0102A S5M0103A
S5M0104A S5M0105B
S5M0106A S5M0107A
BS-10
DATUM POINTS
Body Structure

S5M0108A S5M0109A
S5M0110A S5M0111A
S5M0112A
S5M0113A
S5M0114A S5M0115A
BS-11
DATUM POINTS Body Structure

S5M0116A S5M0117A
S5M0118A
S5M0516A
S5M0120A S5M0121A
S5M0122A S5M0123B
BS-12
DATUM POINTS
Body Structure

S5M0124A S5M0125A
S5M0126B S5M0127A
S5M0128A
S5M0129A
S5M0130A
S5M0131A
BS-13
DATUM POINTS Body Structure

S5M0132A S5M0133A
S5M0134A S5M0135A
S5M0136A
BS-14
DATUM POINTS
Body Structure

3. Datum Dimensions S906337
A: MEASUREMENT S906337A14
Refer to LOCATION for details on measurement
points. <Ref. to BS-3, LOCATION, Datum Points.>
NOTE:
쐌Using a tram tracking gauge, measure all the
dimensions.
쐌When using a tape measure, carefully measure
dimensions without letting the tape measure sag or
twist.
쐌Measure the linear dimensions between CEN-
TERS of holes.
쐌Suffixes “RH”and “LH”indicate right-hand and
left-hand.
G5M0122
쐌Measure at the center of the circle around the
outside of the body panel.
B5M1133A
BS-15
DATUM DIMENSIONS Body Structure

1. FRONT STRUCTURE S906337A1401
S5M0137A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) R to (1) 852 (33.54) (10) R to (8) R 390 (15.35)
(11) L to (1) 913 (35.94) (10) L to (8) L 390 (15.35)
(11) R to (2) 960 (37.80) (11) L to (9) R 659 (25.94)
(11) L to (2) 865 (34.06) (11) R to (9) L 659 (25.94)
(11) R to (9) R 392 (15.43) (9) R to (9) L 966 (38.03)
(11) L to (9) L 392 (15.43) (11) L to (6) R 1,059 (41.69)
(11) R to (6) R 926 (36.46) (11) R to (6) L 1,059 (41.69)
(11) L to (6) L 926 (36.46) (6) R to (6) L 914 (35.98)
(11) R to (3) R 891 (35.08) (6) R to (10) L 1,549 (60.98)
(11) L to (3) L 891 (35.08) (6) L to (10) R 1,549 (60.98)
(10) R to (3) R 917 (36.10) (8) R to (3) R 528 (20.79)
(10) L to (3) L 917 (36.10) (8) L to (3) L 528 (20.79)
(10) R to (10) L 1,374 (54.09) (10) L to (3) R 1,637 (64.45)
(3) R to (3) L 1,338 (52.68) (8) R to (8) L 1,396 (54.96)
(5) R to (5) L 924 (36.38) (8) R to (10) L 1,438 (56.61)
(4) R to (4) L 1,296 (51.02) (8) L to (10) R 1,438 (56.61)
(5) R to (4) L 1,176 (46.30) (3) R to (8) L 1,465 (57.68)
(5) L to (4) R 1,176 (46.30) (3) L to (8) R 1,465 (57.68)
(60) R to (13) R 1,174 (46.22) (7) R to (7) L 860 (33.86)
(60) L to (13) L 1,174 (46.22) (7) R to (6) L 982 (38.66)
(60) R to (14) R 1,076 (42.36) (7) L to (6) R 982 (38.66)
(60) L to (14) L 1,076 (42.36) (7) R to (10) L 1,302 (51.26)
(10) R to (3) L 1,637 (64.45) (7) L to (10) R 1,302 (51.26)
BS-16
DATUM DIMENSIONS
Body Structure

S5M0141A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) to (A) 909.9 (35.82) (11) to (C) 1,097.7 (43.22)
(11) to (B) 915 (36.02) (11) to (D) 1,022 (40.24)
BS-17
DATUM DIMENSIONS Body Structure

2. CENTER STRUCTURE S906337A1402
S5M0138B
BS-18
DATUM DIMENSIONS
Body Structure

3. WINDSHIELD AND DOORS S906337A1403
S5M0139A
BS-19
DATUM DIMENSIONS Body Structure