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
ENGINE2 SECTION
G8050GE3

EXHAUST
EX(DOHC TURBO)
Page
1. General Description.....................................................................................2
2. Front Exhaust Pipe......................................................................................7
3. Center Exhaust Pipe...................................................................................9
4. Joint Pipe...................................................................................................13
5. Rear Exhaust Pipe....................................................................................14
6. Muffler........................................................................................................15

1. General Description S182001
A: COMPONENT S182001A05
1. FRONT EXHAUST PIPE S182001A0501
S2M2237A
EX(DOHC TURBO)-2
GENERAL DESCRIPTION
Exhaust

(1) Gasket
(2) Upper exhaust manifold cover
(RH)
(3) Exhaust manifold (RH)
(4) Lower exhaust manifold cover
(RH)
(5) Front exhaust pipe upper clamp
(6) Front exhaust pipe upper cover
(7) Front exhaust pipe upper insula-
tor (RH)
(8) Front exhaust pipe upper insula-
tor (LH)
(9) Gasket
(10) Front exhaust pipe
(11) Front exhaust pipe lower insula-
tor (RH)
(12) Front exhaust pipe lower insula-
tor (LH)
(13) Front exhaust pipe lower cover
(14) Front exhaust pipe lower clamp
(15) Gasket
(16) Gasket
(17) Upper exhaust manifold cover
(LH)
(18) Exhaust manifold (LH)
(19) Lower exhaust manifold cover
(LH)
(20) Gasket
(21) Turbocharger joint pipe
(22) Gasket
(23) Front oxygen (A/F) sensor
(24) Precatalytic converter
(25) Exhaust temperature sensor
Tightening torque: N·m (kgf-m, ft-lb)
T1: 18.6 (1.9, 13.7)
T2: 25 (2.5, 18.1)
T3: 35 (3.6, 26.0)
T4: 39 (4, 28.9)
EX(DOHC TURBO)-3
GENERAL DESCRIPTION Exhaust

2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER S182001A0502
쐌AUSTRALIA SPEC. VEHICLES
S2M2239A
(1) Gasket
(2) Rear oxygen converter
(3) Upper center pipe cover
(4) Center exhaust pipe
(5) Lower center pipe cover
(6) Bracket (MT)
(7) Gasket
(8) Rear exhaust pipe
(9) Upper cover
(10) Lower cover
(11) Upper cover A
(12) Lower cover A
(13) Spring
(14) Bolt
(15) Cushion
(16) Gasket
(17) Cushion
(18) Muffler
(19) Muffler cutter
Tightening torque: N·m (kgf-m, ft-lb)
T1: 18 (1.8, 13.0)
T2: 30 (3.1, 22.4)
T3: 35 (3.6, 26.0)
T4: 48 (4.9, 35.4)
EX(DOHC TURBO)-4
GENERAL DESCRIPTION
Exhaust

쐌EXCEPT AUSTRALIA SPEC. VEHICLES
S2M2176B
(1) Gasket
(2) Front catalytic converter
(3) Upper center pipe cover (Front)
(4) Center exhaust pipe (Front)
(5) Lower center pipe cover (Front)
(6) Bracket
(7) Gasket
(8) Upper center pipe cover (Rear)
(9) Lower center pipe cover (Rear)
(10) Upper rear catalytic converter
cover
(11) Lower clamp
(12) Lower rear catalytic converter
cover
(13) Rear oxygen sensor
(14) Rear catalytic converter
(15) Upper clamp
(16) Gasket
(17) Rear exhaust pipe
(18) Lower rear exhaust pipe cover
(Front)
(19) Chamber
(20) Lower rear exhaust pipe cover
(Rear)
(21) Cushion
(22) Spring
(23) Bolt
(24) Upper rear exhaust pipe cover
(Front)
(25) Upper rear exhaust pipe cover
(Rear)
(26) Gasket
(27) Muffler
(28) Cushion
(29) Muffler cutter
(30) Center exhaust pipe (Rear)
Tightening torque: N·m (kgf-m, ft-lb)
T1: 18 (1.8, 13.0)
T2: 30 (3.1, 22.4)
T3: 35 (3.6, 26.0)
T4: 48 (4.9, 35.4)
EX(DOHC TURBO)-5
GENERAL DESCRIPTION Exhaust

B: CAUTION S182001A03
쐌Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
쐌Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
쐌Keep the disassembled parts in order and pro-
tect them from dust or dirt.
쐌Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary
removal, installation, disassembly, and replace-
ment.
쐌Be careful not to burn your hands, because each
part on the vehicle is hot after running.
쐌Be sure to tighten fasteners including bolts and
nuts to the specified torque.
쐌Place shop jacks or safety stands at the speci-
fied points.
쐌Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.
EX(DOHC TURBO)-6
GENERAL DESCRIPTION
Exhaust

2. Front Exhaust Pipe S182065
A: REMOVAL S182065A18
1) Disconnect battery ground cable.
G6M0095
2) Remove front oxygen (A/F) sensor. <Ref. to
FU(DOHC TURBO)-42, REMOVAL, Front Oxygen
(A/F) Sensor.>
3) Remove under cover.
4) Remove lower exhaust manifold cover (RH).
5) Remove lower and upper exhaust manifold
covers (LH).
G2M0852
6) Remove bolts and nuts which hold front
exhaust pipe assembly to turbocharger joint pipe.
7) While holding front exhaust pipe assembly with
one hand, remove nuts which hold front exhaust
pipe assembly to cylinder head exhaust port.
G2M0853
8) Remove front exhaust pipe assembly.
9) Remove covers from exhaust manifold and
front exhaust pipe.
10) Separate front exhaust pipe from exhaust
mani-folds.
G2M0854
B: INSTALLATION S182065A11
CAUTION:
Replace gaskets with new ones.
1) Assemble front exhaust pipe and exhaust mani-
folds.
Tightening torque:
39 N·m (4 kgf-m, 28.9 ft-lb)
G2M0854
2) Install front exhaust pipe covers.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Install upper exhaust manifold cover (RH).
Tightening torque:
18.6 N·m (1.9 kgf-m, 13.7 ft-lb)
4) Install front exhaust pipe assembly.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
EX(DOHC TURBO)-7
FRONT EXHAUST PIPE Exhaust

5) Connect exhaust manifold (RH) to turbocharger
joint pipe.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
G2M0853
6) Install upper and lower exhaust manifold covers
(LH).
Tightening torque:
18.6 N·m (1.9 kgf-m, 13.7 ft-lb)
7) Install lower exhaust manifold cover (RH).
Tightening torque:
18.6 N·m (1.9 kgf-m, 13.7 ft-lb)
G2M0852
8) Install front oxygen (A/F) sensor. <Ref. to
FU(DOHC TURBO)-43, INSTALLATION, Front
Oxygen (A/F) Sensor.>
9) Install under cover.
10) Connect battery ground cable.
G6M0095
EX(DOHC TURBO)-8
FRONT EXHAUST PIPE
Exhaust

3. Center Exhaust Pipe S182067
A: REMOVAL S182067A18
1) Set the vehicle on the lift.
2) Disconnect battery ground cable.
3) Remove intercooler. <Ref. to IN(DOHC
TURBO)-10, REMOVAL, Intercooler.>
4) Remove intercooler bracket.
H2M1928
5) Lift-up the vehicle.
6) Remove under cover.
7) Remove universal joint bolts and then remove
universal joint (RHD model only).
CAUTION:
Scribe alignment marks on universal joint so
that it can be reassembled at the original ser-
ration.
H2M1950
8) Remove bolts which install the lower side of
turbocharger upper cover.
CAUTION:
Be careful, turbocharger and exhaust pipe are
hot.
H2M1929
9) Lower the vehicle.
10) Remove turbocharger upper cover.
H2M1733
11) Remove bolts which install the upper side of
turbocharger lower cover, and remove it.
H2M1931
EX(DOHC TURBO)-9
CENTER EXHAUST PIPE Exhaust

12) Separate center exhaust pipe from turbo-
charger.
H2M1745
13) Lift-up the vehicle.
14) Disconnect connector from rear oxygen sen-
sor.
EN0834
15) Separate center exhaust pipe from rear
exhaust pipe.
G2M0855
16) Remove bolt which holds center exhaust pipe
bracket to transmission.
H2M1746
17) Remove intercooler bracket.
18) Remove bolt which holds center exhaust pipe
to hanger bracket.
CAUTION:
Be careful not to pull down center exhaust
pipe.
S2M1723
19) Remove center exhaust pipe.
H2M1762
B: INSTALLATION S182067A11
CAUTION:
Replace gaskets with new ones.
1) Install center exhaust pipe and temporarily
tighten bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten bolt which holds center pipe
to transmission.
3) Connect center exhaust pipe to turbocharger.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
H2M1745
EX(DOHC TURBO)-10
CENTER EXHAUST PIPE
Exhaust

4) Install center exhaust pipe to rear exhaust pipe.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
G2M0855
5) Connect connector to rear oxygen sensor.
EN0834
6) Tighten bolt which holds center exhaust pipe
bracket to transmission.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
H2M1746
7) Tighten bolt which holds center exhaust pipe to
hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26 ft-lb)
S2M1723
8) Tighten bolts which hold intercooler bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
9) Lower the vehicle.
10) Place turbocharger lower cover, and tighten
bolts which install the upper side of lower cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
H2M1931
11) Place turbocharger upper cover, and tighten
bolts which install the upper side of upper cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
H2M1930
12) Lift-up the vehicle.
EX(DOHC TURBO)-11
CENTER EXHAUST PIPE Exhaust

13) Tighten bolts which install the under side of
turbocharger upper cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
H2M1929
14) Install universal joint (RHD model only).
(1) Align bolt hole on the long yoke side of uni-
versal joint with the cutout at the serrated sec-
tion of shaft end, and insert universal joint.
(2) Align bolt hole on the short yoke side of
universal joint with the cutout at the serrated
section of gearbox assembly. Lower universal
joint completely.
(3) Temporarily tighten bolt on the short yoke
side. Raise universal joint to make sure the bolt
is properly passing through the cutout at the
serrated section.
(4) Tighten bolt on the long yoke side, then that
on the short yoke side.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
쐌Make sure that universal joint bolts are tight-
ened through notches in shaft serration.
쐌Excessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
H2M1950
15) Install under cover.
16) Lower the vehicle.
17) Install intercooler bracket.
S2M1928
18) Install intercooler. <Ref. to IN(DOHC
TURBO)-10, INSTALLATION, Intercooler.>
19) Align center of roll connector. (With airbag
model) <Ref. to AB-11, ROLL CONNECTOR,
INSPECTION, Inspection Locations After a Colli-
sion.>
EX(DOHC TURBO)-12
CENTER EXHAUST PIPE
Exhaust

4. Joint Pipe S182771
A: REMOVAL S182771A18
1) Disconnect battery ground cable.
G6M0095
2) Remove solenoid valve cover.
EN0828
3) Disconnect from exhaust temperature sensor
connector.
EN0896
4) Remove front oxygen (A/F) sensor. <Ref. to
FU(DOHC TURBO)-42, REMOVAL, Front Oxygen
(A/F) Sensor.>
5) Remove under cover.
6) Remove lower exhaust manifold cover (RH).
G2M0852
7) Remove nuts. Which hold front exhaust mani-
fold to joint pipe.
EN0917
8) Remove center exhaust pipe. <Ref. to
EX(DOHC TURBO)-9, REMOVAL, Center Exhaust
Pipe.>
9) Remove turbocharger. <Ref. to IN(DOHC
TURBO)-12, REMOVAL, Turbocharger.>
10) Take off joint pipe in the upward direction.
B: INSTALLATION S182771A11
Install in the reverse order of removal.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
H2M1747A
EX(DOHC TURBO)-13
JOINT PIPE Exhaust

5. Rear Exhaust Pipe S182068
A: REMOVAL S182068A18
1) Disconnect battery ground cable.
G6M0095
2) Lift up the vehicle.
3) Separate rear exhaust pipe from center
exhaust pipe.
CAUTION:
Be careful, exhaust pipe is hot.
S2M0558
4) Separate rear exhaust pipe from muffler.
CAUTION:
Be careful not to pull down rear exhaust pipe.
S2M0559
5) Remove rear exhaust pipe.
B: INSTALLATION S182068A11
CAUTION:
Replace gaskets with new ones.
1) Install rear exhaust pipe to muffler.
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
S2M0559
2) Install rear exhaust pipe to center exhaust pipe.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S2M0558
3) Lower the vehicle.
4) Connect battery ground cable.
G6M0095
C: INSPECTION S182068A10
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.
EX(DOHC TURBO)-14
REAR EXHAUST PIPE
Exhaust

6. Muffler S182066
A: REMOVAL S182066A18
1) Separate muffler from rear exhaust pipe.
CAUTION:
Be careful, exhaust pipe is hot.
S2M0559
2) Remove rubber cushions, and detach muffler.
CAUTION:
Be careful not to drop the muffler during
removal.
NOTE:
To facilitate removal, apply a coat of SUBARU
CRC to mating area of rubber cushions in
advance.
SUBARU CRC (Part No. 004301003)
S2M2177
B: INSTALLATION S182066A11
Install in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
S2M0559
C: INSPECTION S182066A10
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.
EX(DOHC TURBO)-15
MUFFLER Exhaust

MEMO:
EX(DOHC TURBO)-16
Exhaust MUFFLER