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

(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

, 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

, 85 psi)

294 N (30 kgf, 66 lb) 1,667 kPa (17 kg/cm

, 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

, 782 psi)

294 N (30 kgf, 66 lb) 10,003 kPa (102 kg/cm

, 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

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