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
CHASSIS SECTION
G8050GE5

BRAKE BR
Page
1. General Description.....................................................................................2
2. Front Brake Pad........................................................................................20
3. Front Disc Rotor........................................................................................22
4. Front Disc Brake Assembly.......................................................................23
5. Rear Brake Pad.........................................................................................26
6. Rear Disc Rotor.........................................................................................27
7. Rear Disc Brake Assembly .......................................................................29
8. Rear Drum Brake Shoe.............................................................................32
9. Rear Drum Brake Drum............................................................................34
10. Rear Drum Brake Assembly......................................................................35
11. Master Cylinder.........................................................................................38
12. Brake Booster............................................................................................40
13. Proportioning Valve...................................................................................44
14. Brake Fluid................................................................................................45
15. Air Bleeding...............................................................................................47
16. Brake Hose................................................................................................49
17. Brake Pipe.................................................................................................50
18. Hill Holder..................................................................................................51
19. Brake Pedal...............................................................................................54
20. Stop Light Switch ......................................................................................60
21. General Diagnostics..................................................................................62

1. General Description S405001
A: SPECIFICATIONS S405001E49
Engine (cc) 2000
Driving system AWD
Model Others Non-TURBO
Australia TURBO
Front
disc
brake
Type Disc (Floating type, ventilated)
Effective disc diameter mm (in) 228 (8.98)
Disc thickness ×Outer diameter mm (in) 24 ×277 (0.94 ×10.91)
Effective cylinder diameter mm (in) 42.8 (1.685) ×2
Pad dimensions
(length ×width ×thickness*) mm (in) 112.3 ×50.0 ×17.0 (4.42 ×1.969 ×0.669)
Clearance adjustment Automatic adjustment
Rear
disc
brake
Type —Disc (Floating type)
Effective disc diameter mm (in) —230 (9.06)
Disc thickness ×Outer diameter mm (in) —10 ×266 (0.39 ×10.47)
Effective cylinder diameter mm (in) —38.1 (1.500)
Pad dimensions
(length ×width ×thickness*) mm (in) —82.4 ×33.7 ×14.0 (3.244 ×1.327 ×0.551)
Clearance adjustment —Automatic adjustment
Rear
drum
brake
Type Drum
(Leading-Trailing type) —
Effective drum diameter mm (in) 228.6 (9) —
Effective cylinder diameter mm (in) 19.0 (0.748) —
Lining dimensions
(length ×width ×thickness) mm (in) 218.8 ×35.0 ×4.1 (8.61 ×1.378 ×0.161) —
Clearance adjustment Automatic adjustment —
Master
cylinder
Type Tandem
Effective diameter mm (in) 26.99 (1-1/16)
Reservoir type Sealed type
Brake fluid reservoir capacity cm
3
(cu in) 205 (12.51)
Brake
booster Type Vacuum suspended
Effective diameter mm (in) 205 + 230 (8.07 + 9.06)
Propor-
tioning
valve
Split point kPa (kg/cm
2
, psi) 3,678 (37.5, 533)
Reducing ratio 0.3
Brake line Dual circuit system
ABS OP STD
Brake fluid FMVSS No. 116, DOT3 or DOT4
*: Including back metal
NOTE:
Refer to “PB section”for parking brake SPECIFICATIONS. <Ref. to PB-2, General Description.>
BR-2
GENERAL DESCRIPTION
Brake

ITEM STANDARD SERVICE LIMIT
Front brake
Pad thickness
(including back metal) 17 mm (0.67 in) 7.5 mm (0.295 in)
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout —0.075 mm (0.0030 in)
Rear brake (Disc type)
Pad thickness
(including back metal) 14 mm (0.55 in) 6.5 mm (0.256 in)
Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in)
Disc runout —0.070 mm (0.0028 in)
Rear brake (Drum type) Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in)
Rear brake (Disc type parking) Inside diameter 170 mm (6.69 in) 171 mm (6.73 in)
Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Parking brake Lever stroke 7 to 8 notches/196 N (20 kgf, 44 lb)
Brake booster
Brake pedal force Fluid pressure
Brake fluid pressure without
engine running 147 N (15 kgf, 33 lb) 588 kPa (6 kg/cm
2
, 85 psi)
294 N (30 kgf, 66 lb) 1,667 kPa (17 kg/cm
2
, 242 psi)
Brake fluid pressure with engine
running and vacuum at 66.7 kPa
(500 mmHg, 19.69 inHg)
147 N (15 kgf, 33 lb) 5,394 kPa (55 kg/cm
2
, 782 psi)
294 N (30 kgf, 66 lb) 10,003 kPa (102 kg/cm
2
, 1,450 psi)
Brake pedal Free play 1—3 mm (0.04 —0.12 in)
[Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).]
BR-3
GENERAL DESCRIPTION Brake

B: COMPONENT S405001A05
1. FRONT DISC BRAKE S405001A0511
B4M1151C
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Boot ring
(9) Lock pin (Yellow)
(10) Support
(11) Pad clip
(12) Outer shim (For Australia)
(13) Inner shim (For Australia)
(14) Pad (Outside)
(15) Pad (Inside)
(16) Disc rotor
(17) Disc cover
Tightening torque: N·m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 39 (4.0, 28.9)
T4: 78 (8.0, 58)
BR-4
GENERAL DESCRIPTION
Brake

2. REAR DISC BRAKE S405001A0503
H4M1355A
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Boot ring
(9) Lock pin (Yellow)
(10) Support
(11) Pad clip
(12) Inner pad
(13) Outer pad
(14) Shim
(15) Shoe hold-down pin
(16) Cover
(17) Back plate
(18) Retainer
(19) Spring washer
(20) Parking brake lever
(21) Parking brake shoe (Secondary)
(22) Parking brake shoe (Primary)
(23) Strut
(24) Strut shoe spring
(25) Shoe guide plate
(26) Secondary shoe return spring
(27) Primary shoe return spring
(28) Adjusting spring
(29) Adjuster
(30) Shoe hold-down cup
(31) Shoe hold-down spring
(32) Disc rotor
Tightening torque: N·m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 39 (4.0, 28.9)
T3: 52 (5.3, 38.3)
BR-5
GENERAL DESCRIPTION Brake

3. REAR DRUM BRAKE S405001A0504
B4M1120A
(1) Air bleeder cap
(2) Air bleeder screw
(3) Boot
(4) Piston
(5) Cup
(6) Spring
(7) Wheel cylinder body
(8) Pin
(9) Plug
(10) Back plate
(11) Upper shoe return spring
(12) Retainer
(13) Washer
(14) Parking brake lever
(15) Brake shoe (Trailing)
(16) Brake shoe (Leading)
(17) Shoe hold-down spring
(18) Cup
(19) Adjusting lever
(20) Adjuster
(21) Lower shoe return spring
(22) Adjusting spring
(23) Drum
(24) Plug
Tightening torque: N·m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 10 (1.0, 7.2)
T3: 52 (5.3, 38.3)
BR-6
GENERAL DESCRIPTION
Brake

4. MASTER CYLINDER S405001A0505
쐌LHD model
S4M0325B
(1) Cap
(2) Filter
(3) Reservoir tank
(4) Piston retainer
(5) Primary piston
(6) Secondary piston
(7) Cylinder body
(8) Cylinder pin (With ABS)
(9) Seal
(10) Pin
Tightening torque: N·m (kgf-m, ft-lb)
T: 14 (1.4, 10.1)
BR-7
GENERAL DESCRIPTION Brake

쐌RHD model
B4M1155D
(1) Cap
(2) Filter
(3) Reservoir tank
(4) Bracket
(5) Piston retainer
(6) Primary piston
(7) Secondary piston
(8) Cylinder body
(9) Cylinder pin (With ABS)
(10) Seal
(11) Pin
Tightening torque: N·m (kgf-m, ft-lb)
T: 14 (1.4, 10.1)
BR-8
GENERAL DESCRIPTION
Brake

5. HILL HOLDER S405001A0510
S4M0240A
(1) Clamp
(2) PHV cable
(3) PHV (Pressure hold valve)
(4) Adjusting nut
(5) Lock nut Tightening torque: N·m (kgf-m, ft-lb)
T1: 3.5 (0.35, 2.5)
T2: 18 (1.8, 13.0)
BR-9
GENERAL DESCRIPTION Brake