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

EXTERIOR BODY PANELS EB
Page
1. General Description.....................................................................................2
2. Front Hood ..................................................................................................9
3. Fender Panel.............................................................................................10
4. Front Door Panel.......................................................................................11
5. Front Sealing Cover..................................................................................13
6. Rear Door Panel .......................................................................................14
7. Rear Sealing Cover...................................................................................16
8. Rear Gate Panel .......................................................................................17

1. General Description S913001
A: SPECIFICATIONS S913001E49
S5M0380A
EB-2
GENERAL DESCRIPTION
Exterior Body Panels

B: COMPONENT S913001A05
1. FRONT HOOD S913001A0501
S5M0442A
(1) Front hood
(2) Striker
(3) Hinge
(4) Seal
(5) Front hood stay Tightening torque: N·m (kg-m, ft-lb)
T1: 24.5 (2.5, 18.1)
T2: 33 (3.4, 25)
EB-3
GENERAL DESCRIPTION Exterior Body Panels

2. FRONT DOOR PANEL S913001A0502
S5M0506A
(1) Gusset
(2) Weatherstrip
(3) Stabilizer (Outer)
(4) Stabilizer (Inner)
(5) Door panel
(6) Checker
(7) Sealing cover
(8) Lower hinge
(9) Upper hinge
Tightening torque: N·m (kgf-m, ft-lb)
T1: 7.35 (0.75, 5.4)
T2: 13 (1.3, 9.4)
T3: 25 (2.5, 18)
T4: 30 (3.1, 22)
T5: 32 (3.3, 24)
EB-4
GENERAL DESCRIPTION
Exterior Body Panels

3. REAR DOOR PANEL S913001A0503
S5M0507A
(1) Weatherstrip
(2) Stabilizer (Outer)
(3) Stabilizer (Inner)
(4) Door panel
(5) Plate
(6) Sealing cover
(7) Checker
(8) Lower hinge
(9) Upper hinge
Tightening torque: N·m (kgf-m, ft-lb)
T1: 7.35 (0.75, 5.4)
T2: 25 (2.5, 18)
T3: 30 (3.1, 18)
T4: 32 (3.3, 24)
EB-5
GENERAL DESCRIPTION Exterior Body Panels

4. REAR GATE PANEL S913001A0505
S5M0443B
(1) Gas stay
(2) Hinge
(3) Rear gate
(4) Stopper
(5) Buffer cover
(6) Buffer (Back door) Tightening torque: N·m (kg-m, ft-lb)
T1: 7.5 (0.76, 5.5)
T2: 14 (1.4, 10.1)
T3: 25 (2.5, 18.1)
EB-6
GENERAL DESCRIPTION
Exterior Body Panels

C: CAUTION S913001A03
쐌Exterior body panels are heavy. Do not drop and
damage the panels. During removal and
installation, do not damage the panel painting sur-
face.
쐌While removing mounting bolts, using assis-
tance devices such as a support jack will help sup-
port the panel.
쐌Be careful not to lose small parts.
EB-7
GENERAL DESCRIPTION Exterior Body Panels

D: PREPARATION TOOL S913001A17
1. SPECIAL TOOLS S913001A1701
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B5M1117
925610000 WRENCH Used for removing and installing door hing.
2. GENERAL TOOL S913001A1702
TOOL NAME REMARKS
Support Jack Used for supporting door panel.
EB-8
GENERAL DESCRIPTION
Exterior Body Panels

2. Front Hood S913367
A: REMOVAL S913367A18
1) Open front hood to remove washer nozzles.
2) Remove bolts to detach hood from hinges.
G5M0137
B: INSTALLATION S913367A11
1) Install in the reverse order of removal.
2) Adjust clearance between hood and fender.
Clearance must be equal at both sides.
C: ADJUSTMENT S913367A01
1) Use hinge mounting holes to align front hood
longitudinally and laterally.
G5M0137
2) Adjust height at front end of hood. <Ref. to
SL-38 ADJUSTMENT, Front Hood Lock Assem-
bly.>
3) Rotate hood buffer to adjust lateral height.
G5M0141
EB-9
FRONT HOOD Exterior Body Panels

3. Fender Panel S913368
A: REMOVAL S913368A18
1) Disconnect ground (−) cable from battery.
2) Remove side protectors and fender protectors.
<Ref. to EI-22, REMOVAL, Protector.>
3) Remove mud guard. <Ref. to EI-21 REMOVAL,
Mud Guard.>
4) Remove front bumper face. <Ref. to EI-12
REMOVAL, Front Bumper.>
5) Remove headlights. <Ref. to LI-42 REMOVAL,
Headlight Assembly.>
6) Remove bolts to remove front fender.
S5M0165
B: INSTALLATION S913368A11
1) Install in the reverse order of removal.
2) When fender panel is installed, clearance
between fender panel and hood or front fender
must be equal.
EB-10
FENDER PANEL
Exterior Body Panels

4. Front Door Panel S913366
A: REMOVAL S913366A18
1) Disconnect (−) cable from battery.
2) Remove front door trim. <Ref. to EI-26
REMOVAL, Front Door Trim.>
3) Remove outer mirror assembly. <Ref. to GW-49
REMOVAL, Outer Mirror Assembly.>
4) Remove front door glass. <Ref. to GW-28,
REMOVAL, Front Door Glass.>
5) Remove front door regulator and motor. <Ref.
to GW-31 REMOVAL, Front Regulator and Motor.>
6) Remove front door latch assembly. <Ref. to
SL-29 REMOVAL, Front Door Latch Assembly.>
7) Remove front outer handle. <Ref. to SL-28
REMOVAL, Front Outer Handle.>
8) Remove front pillar lower trim to disconnect
connector from body harness.
B5M0726
9) Put wooden block on jack and place jack under
door. Support door with a jack to protect it from
damage.
S5M0518
10) Remove checker bolts.
S5M0183
11) Remove door-side bolts for upper and lower
hinges to remove door.
G5M0385
12) Using special tool, remove body-side bolts for
upper and lower hinges, and remove door hinges.
ST 925610000 DOOR HINGE WRENCH
B5M0933A
CAUTION:
쐌During removal and installation of doors, do
not damage body.
쐌Doors are heavy. Be careful not to drop and
damage them.
B: INSTALLATION S913366A11
1) Install in the reverse order of removal.
2) Apply grease to sliding area of door hinges.
EB-11
FRONT DOOR PANEL Exterior Body Panels

C: ADJUSTMENT S913366A01
1) Using special tool, loosen body-side bolts of
upper and lower hinges to align the position of front
door panel longitudinally and vertically.
ST 925610000 DOOR HINGE WRENCH
B5M0933A
2) Loosen door-side bolts of upper and lower
hinges to align the position of front door panel ver-
tically and laterally at the front end.
G5M0385
3) Loosen screw (A) and lightly tap striker (B)
using plastic hammer to adjust striker to align the
position of front door panel vertically and laterally
at the rear end.
B5M0934A
CAUTION:
Do not use impact wrench. Welding area on
striker nut plate is easily broken.
EB-12
FRONT DOOR PANEL
Exterior Body Panels

5. Front Sealing Cover S913564
A: REMOVAL S913564A18
1) Remove front door trim. <Ref. to EI-26
REMOVAl, Front Door Trim.>
2) Remove front speaker. <Ref. to EI-12
REMOVAL, Front Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
쐌Carefully remove sealer. Excessive force will
easily break the cover.
쐌If cover gets broken, replace it with a new
one.
G5M0391
B: INSTALLATION S913564A11
1) Install in the reverse order of removal.
2) When replacing sealing cover, use CEMEDINE
5430L sealer.
3) Press sealer-applied area firmly to prevent any
floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
쐌Apply a uniform bead of sealer.
쐌Attach sealing cover, keeping it from becom-
ing wrinkled.
쐌Breaks in the bead will allow water leakage
and contamination.
C: INSPECTION S913564A10
If sealing cover is damaged, replace it with a new
one.
EB-13
FRONT SEALING COVER Exterior Body Panels

6. Rear Door Panel S913364
A: REMOVAL S913364A18
1) Disconnect (−) cable from battery.
2) Remove rear door trim. <Ref. to EI-27
REMOVAL, Rear Door Trim.>
3) Remove rear door glass. <Ref. to GW-32,
REMOVAL, Rear Door Glass.>
4) Remove rear door regulator and motor assem-
bly. <Ref. to GW-34 REMOVAL, Rear Regulator
and Motor Assembly.>
5) Remove rear outer handle. <Ref. to SL-32
REMOVAL, Rear Outer Handle.>
6) Remove center pillar lower trim. <Ref. to EI-38
REMOVAL, Lower Inner Trim.>
7) Remove seatbelt bracket and blind plug.
Disconnect connector of door harness and remove
door hinge nut.
B5M1062
8) Put a wooden block on the jack and place the
jack under the door. Support the door with the jack
to protect it.
S5M0518
9) Remove checker bolts.
S5M0183
10) Remove door-side bolts for upper and lower
hinges to remove door.
G5M0385
11) Using special tool, remove body-side bolts for
upper and lower hinges, and remove door hinges.
CAUTION:
쐌During removal and installation of doors, do
not damage body.
쐌Doors are heavy. Be careful not to drop and
damage them.
B: INSTALLATION S913364A11
1) Install in the reverse order of removal.
2) Apply grease to sliding area of door hinges.
EB-14
REAR DOOR PANEL
Exterior Body Panels

C: ADJUSTMENT S913364A01
1) Using special tool, loosen body-side bolts of
upper and lower hinges to align the position of rear
door panel longitudinally and vertically.
B5M0933A
2) Loosen door-side bolts of upper and lower
hinges to align the position of rear door panel ver-
tically and laterally at front-end.
G5M0385
3) Loosen screw (A) and lightly tap striker (B)
using plastic hammer to adjust striker to align the
position of front door panel vertically and laterally
at the rear end.
B5M0934A
CAUTION:
Do not use an impact wrench. The welding area
on the striker nut plate is easily broken.
EB-15
REAR DOOR PANEL Exterior Body Panels

7. Rear Sealing Cover S913565
A: REMOVAL S913565A18
1) Remove rear door trim. <Ref. to EI-27
REMOVAL, Rear Door Trim.>
2) Remove rear speaker. <Ref. to ET-13
REMOVAL, Rear Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
쐌Carefully remove sealer. Excessive force will
easily break the cover.
쐌If cover gets broken, replace it with a new
one.
G5M0391
B: INSTALLATION S913565A11
1) Install in the reverse order of removal.
2) When replacing sealing cover, use CEMEDINE
5430L sealer.
3) Press sealer-applied area firmly to prevent any
floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
쐌Apply an uniform bead of sealer.
쐌Attach sealing cover, keeping it from becom-
ing wrinkled.
쐌Breaks in the bead will allow water leakage
and contamination.
C: INSPECTION S913565A10
If sealing cover gets damaged, replace it with a
new one.
EB-16
REAR SEALING COVER
Exterior Body Panels

8. Rear Gate Panel S913363
A: REMOVAL S913363A18
1. REAR GATE PANEL S913363A1801
1) Open rear gate.
2) Remove rear gate outer handle. <Ref. to SL-35
REMOVAL, Rear Gate Outer Handle.>
3) Remove rear gate latch assembly. <Ref. to
SL-36 REMOVAL, Rear Gate Latch Assembly.>
4) Remove rear gate key lock cylinders. <Ref. to
SL-41 REMOVAL, Key Lock Cylinders.>
5) Remove rear wiper. <Ref. to WW-20
REMOVAL, Rear Wiper Motor.>
6) Disconnect connectors of rear wiper, rear
defogger, and other lighting devices.
7) Disconnect washer hose.
8) Remove rubber duct (A) connection, and pull
out harness and washer hose from rear gate.
B5M0733A
9) Using a support, support the rear gate while
removing gas stay mounting bolts.
10) Loosen rear gate bolts to remove rear gate.
BO0262
S5M0206
CAUTION:
When the rear gate is released, it may hit and
damage the body. To prevent this, place a shop
cloth between body and gate.
2. GAS STAY S913363A1802
1) Open rear gate. Using a jack to support the rear
gate.
BO0262
CAUTION:
쐌After gas stay is removed, rear gate cannot
stay open. Supporting the rear gate with a jack,
remove the bolts.
쐌Do not damage piston rods and oil seals.
쐌Never disassemble cylinders: They contain
gas.
2) Loosen bolts to remove gas stay from rear gate.
B: INSTALLATION S913363A11
1. REAR GATE PANEL S913363A1101
1) Install in the reverse order of removal.
2) Install rear gate panel with uniform clearance to
body.
CAUTION:
Do not damage painted surfaces of body and
rear gate.
2. GAS STAY S913363A1102
Install in the reverse order of removal.
CAUTION:
쐌Do not confuse right and left sides of gas
stay.
쐌After supporting rear gate with a jack, start
operation.
EB-17
REAR GATE PANEL Exterior Body Panels

C: DISPOSAL S913363A07
1. GAS STAY S913363A0701
CAUTION:
Gas is colorless, odorless, and harmless.
However, gas pressure may spray cutting pow-
der or oil. Be sure to wear dust-resistant
goggles.
1) Cover with a vinyl case as shown in the figure.
BO0264
CAUTION:
Prevent the vinyl case from being caught by
drill cutting edge
2) Lift body side slightly with piston rods fully
extended, and secure body side on vise stand.
Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter
at a point 10 to 200 mm (0.39 to 7.87 in) from door
side, and bleed gas stay completely.
BO0263
EB-18
REAR GATE PANEL
Exterior Body Panels