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

6. BRAKE PIPES AND HOSE S405001A0506
쐌Front brake pipe for model with ABS (LHD)
S4M0533A
(1) Front brake pipe assembly
(2) Proportioning valve
(3) Front brake hose RH
(4) Front brake hose LH
(5) Clamp
(6) Gasket
(7) ABS control module and hydrau-
lic control unit
(8) Bracket
(9) Master cylinder
(10) Hill holder
(11) Adapter pipe
Tightening torque: N·m (kgf-m, ft-lb)
T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
쐌Front brake pipe for model with ABS (RHD)
S4M0534A
(1) Front brake pipe assembly
(2) Proportioning valve
(3) Front brake hose RH
(4) Front brake hose LH
(5) Clamp
(6) Gasket
(7) ABS control module and hydrau-
lic control unit
(8) Bracket
(9) Master cylinder
(10) Hill holder
(11) Adapter pipe
Tightening torque: N·m (kgf-m, ft-lb)
T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
BR-10
GENERAL DESCRIPTION
Brake

쐌Front brake pipe for model without ABS (LHD)
S4M0535A
(1) Front brake pipe assembly
(2) Proportioning valve
(3) Front brake hose RH
(4) Front brake hose LH
(5) Clamp
(6) Gasket
(7) Bracket
(8) Master cylinder
(9) Hill holder
(10) Adapter pipe
Tightening torque: N·m (kgf-m, ft-lb)
T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
쐌Front brake pipe for model without ABS (RHD)
S4M0536A
(1) Front brake pipe assembly
(2) Proportioning valve
(3) Front brake hose RH
(4) Front brake hose LH
(5) Clamp
(6) Gasket
(7) Bracket
(8) Master cylinder
(9) Hill holder
(10) Adapter pipe
Tightening torque: N·m (kgf-m, ft-lb)
T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
BR-11
GENERAL DESCRIPTION Brake

쐌Center and rear brake pipe
S4M0537A
(1) Center brake pipe assembly
(2) Clamp
(3) Rear brake hose RH (With ABS)
(4) Gasket
(5) Rear brake pipe RH (Without
ABS)
(6) Rear brake hose RH (Without
ABS)
(7) Rear brake pipe assembly
(8) Two-way connector
(9) Rear brake hose LH (With ABS)
(10) Rear brake hose LH (Without
ABS)
(11) Rear brake pipe LH (Without
ABS)
Tightening torque: N·m (kgf-m, ft-lb)
T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
T3: 32 (3.3, 23.6)
BR-12
GENERAL DESCRIPTION
Brake

7. BRAKE BOOSTER S405001A0507
쐌LHD model
S4M0538A
쐌RHD model
S4M0539A
(1) Brake master cylinder
(2) Vacuum hose
(3) Clip
(4) Brake booster assembly
(5) Seal
(6) Clevis pin
(7) Snap pin
(8) Brake pedal
(9) Bracket
(10) Vacuum hose (Non-turbo model)
(11) Vacuum hose (Turbo model)
(12) Vacuum pipe (Turbo model)
Tightening torque: N·m (kgf-m, ft-lb)
T1: 14 (1.4, 10.1)
T2: 18 (1.8, 13.0)
BR-13
GENERAL DESCRIPTION Brake

8. BRAKE PEDAL FOR MT MODEL S405001A0508
쐌LHD model
B4M2467A
(1) Stopper
(2) Bushing
(3) Spring pin
(4) Snap pin
(5) Brake pedal pad
(6) Brake pedal
(7) Clevis pin
(8) Brake pedal spring
(9) Clutch pedal pad
(10) Clutch pedal
(11) Bushing C
(12) Clutch clevis pin
(13) Assist rod A
(14) Clip
(15) Assist spring
(16) Assist bushing
(17) Assist rod B
(18) Spring S
(19) Rod S
(20) Bushing S
(21) O-ring
(22) Clip
(23) Clutch switch (With cruise con-
trol)
(24) Stop light switch
(25) Pedal bracket
(26) Clutch master cylinder bracket
(27) Lever
Tightening torque: N·m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
BR-14
GENERAL DESCRIPTION
Brake

쐌RHD model
S4M0544A
(1) Bushing
(2) Accelerator pedal
(3) Accelerator pedal spring
(4) Spring pin
(5) Accelerator pedal pad
(6) Stopper
(7) Spacer
(8) Clevis pin
(9) Brake pedal pad
(10) Brake pedal
(11) Snap pin
(12) Brake pedal spring
(13) Brake spacer
(14) Clip
(15) Pedal bracket
(16) Stop light switch
(17) Accelerator spring
Tightening torque: N·m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 29 (3.0, 21.7)
BR-15
GENERAL DESCRIPTION Brake

9. BRAKE PEDAL FOR AT MODEL S405001A0509
쐌LHD model
B4M2346A
(1) Stopper
(2) Bushing
(3) Plug
(4) Pedal bracket
(5) Stop light switch
(6) Spacer
(7) Snap pin
(8) Brake pedal pad
(9) Brake pedal
(10) Clevis pin
(11) Brake spacer
(12) Brake pedal spring
Tightening torque: N·m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 30 (3.1, 22.4)
BR-16
GENERAL DESCRIPTION
Brake

쐌RHD model
S4M0321A
(1) Accelerator pedal
(2) Accelerator pedal spring
(3) Spring pin
(4) Accelerator pedal pad
(5) Stopper
(6) Bushing
(7) Kick-down switch
(8) Pedal bracket
(9) Clip
(10) Stop light switch
(11) Accelerator spring
(12) Brake pedal spring
(13) Brake spacer
(14) Brake pedal
(15) Spacer
(16) Clevis pin
(17) Brake pedal pad
(18) Snap pin
Tightening torque: N·m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 29 (3.0, 21.7)
BR-17
GENERAL DESCRIPTION Brake

C: CAUTION S405001A03
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 in the vehicle is hot after running.
쐌Use SUBARU genuine grease etc. or the
equivalent. Do not mix grease etc. with that of
another grade or from other manufacturers.
쐌Be sure to tighten fasteners including bolts and
nuts to the specified torque.
쐌Place shop jacks or safety stands at the speci-
fied points.
쐌Apply grease onto sliding or revolution surfaces
before installation.
쐌Before installing O-rings or snap rings, apply
sufficient amount of grease to avoid damage and
deformation.
쐌Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
쐌Do not put fluid on body. If the body is tainted,
wash away with water.
BR-18
GENERAL DESCRIPTION
Brake

D: PREPARATION TOOL S405001A17
1. SPECIAL TOOLS S405001A1701
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2406
926460000 WHEEL CYLINDER
3/4″ADAPTER Used for installing cup onto wheel cylinder pis- ton (Size 3/4 in).
2. GENERAL PURPOSE TOOLS S405001A1702
TOOL NAME REMARKS
Snap Ring Pliers Used for removing and installing snap ring.
BR-19
GENERAL DESCRIPTION Brake