Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 1999-2000 GENERAL INFORMATION SECTION General Information MSA5T0120A27422

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MSA5T0120A27422


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                              G8040BE1SGML



1-3     [G1A0]                     GENERAL INFORMATION
1. General Precautions


1. General Precautions                                     11)When removing a wiring connector, do not
                                                           pull the wire but pull the connector itself.
A: BEFORE STARTING SERVICE                                 12)When removing a hose or tube, remove the
1) Be sure to perform the jobs listed in the Peri-         clip first. Then, pull the hose or tube while hold-
odic Maintenance Schedule.                                 ing its end fitting.
2) When a vehicle is brought in for mainte-                13)Replace gaskets, O-rings, snap rings, lock
nance, carefully listen to the owner's explana-            washers, etc. with new ones.
tions of the symptoms exhibited by the vehicle.            14)When tightening a bolt or nut, tighten it to the
List the problems in your notebook, and refer to           specified torque.
them when trying to diagnose the trouble.                  15)When performing work requiring special
3) All jewelry should be removed. Suitable                 tools, be sure to use the designated ones.
work clothes should be worn.                               16)After completing work, make certain that the
4) Be sure to wear goggles.                                hoses, tubes and wiring harnesses are securely
5) Use fender, floor and seat covers to prevent            connected.
the vehicle from being scratched or damaged.               17)After completing work, be sure to wash the
6) Never smoke while working.                              vehicle.
7) Before removing underfloor bolts (including
the rear differential filler plug) coated with bitu-       C: TREATMENT FOR USED ENGINE
minous wax, remove old wax. Re-coat with new               OIL
wax after reinstallation.                                  1. ENGINE OILS
B: WHILE WORKING                                           Prolonged and repeated contact with mineral
                                                           oil will result in the removal of natural fats from
1) When jacking up the vehicle, be sure to use             the skin, leading to dryness, irritation and der-
safety stands.                                             matitis. In addition, used engine oil contains po-
2) When jacking up the front or rear end of the            tentially harmful contaminants which may
car body, be sure to chock the tires remaining             cause skin cancer. Adequate means of skin
in contact with the ground.                                protection and washing facilities should be pro-
3) Keep the parking brake applied when work-               vided.
ing on the vehicle. Chock the tires remaining in
contact with the ground (and set the selector le-          2. HEALTH PROTECTION PRECAUTIONS
ver to "P" position in AT vehicle), when the park-         1) Avoid prolonged and repeated contact with
ing brake cannot be applied, such as when the              oils, particularly used engine oils.
brakes are being worked on.                                2) Wear protective clothing, including impervi-
4) Keep the ignition key turned "OFF" if at all            ous gloves where practicable.
possible.                                                  3) Do not put oily rags in pockets.
5) Be cautious while working when the ignition             4) Avoid contaminating clothes, particularly
key is "ON"; if the engine is hot, the cooling fan         underpants, with oil.
may start to operate.                                      5) Overalls must be cleaned regularly. Discard
6) While the engine is in operation, properly              unwashable clothing and oil impregnated foot-
ventilate the workshop.                                    wear.
7) While the engine is in operation, be aware of           6) First aid treatment should be obtained im-
any moving parts, such as the cooling fan and              mediately for open cuts and wounds.
the drive belt.                                            7) Use barrier creams, applying them before
8) Keep your hands off any metal parts such as             each work period, to help the removal of oil from
the radiator, exhaust manifold, exhaust pipe,              the skin.
and muffler to prevent burning yourself.                   8) Wash with soap and water to ensure all oil is
9) When servicing the electrical system or the             removed (skin cleansers and nail brushes will
fuel system, disconnect the ground cable from              help). Preparations containing lanolin replace
the battery.                                               the natural skin oils which have been removed.
10)When disassembling, arrange the parts in
the order that they were disassembled.


                                                       2
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                                   GENERAL INFORMATION                                       [G1E2]     1-3
                                                                                      1. General Precautions


9) Do not use petrol, kerosene, diesel fuel, gas          when engine is operating at low speeds
oil, thinners or solvents for washing skin.               since this may cause vehicle to jump off test
10)If skin disorders develop, obtain medical              machine.
advice.                                                   D Avoid abrupt braking after tests.
11)Where practicable, degrease components                 D In order to prevent the vehicle from slip-
prior to handling.                                        ping due to vibration, do not place any
12)Where there is a risk of eye contact, eye              wooden blocks or similar items between the
protection should be worn, for example, chemi-            safety stands and the vehicle.
cal goggles or face shields; in addition an eye           D Since the rear wheels will also be rotating,
wash facility should be provided.                         do not place anything near them. Also, make
3. ENVIRONMENTAL PROTECTION PRE-                          sure that nobody goes in front of the vehicle.
CAUTIONS                                                  1) Position vehicle so that front wheels are
It is illegal to pour used oil on to the ground,          placed between rollers of speedometer test
down sewers or drains, or into water courses.             machine.
The burning of used engine oil in small space             2) Jack up vehicle until rear wheels clear the
heaters or boilers is not recommended unless              floor, and support with safety stands.
emission control equipment is fitted. If in doubt,
check with the Local Authority.
Dispose of used oil through authorized waste
disposal contractors, licensed waste disposal
sites, or to the waste oil reclamation trade. If in
doubt, contact the Local Authority for advice on
disposal facilities.

D: HANDLING AN AT VEHICLE
1) The engine cannot be started by pushing
the vehicle, and also the vehicle cannot be
                                                                                                  S1H0004A
moved by operating the starter motor.
2) Be sure to release the accelerator pedal be-
fore shifting from the "R" to the "N" range and           3) Start engine with shift lever set in 2nd gear
from the "N" to the "D" range, or vise versa even         (for safety considerations). Perform speedom-
when the vehicle is stopped.                              eter tests.
3) Do not maintain the vehicle in a stall opera-          2. SPEEDOMETER TEST (Free roller meth-
tion for more than five seconds as this may over-         od)
heat the clutch excessively.                              WARNING:
4) When the speedometer malfunctions, a ve-               D Secure a rope or wire to the front towing
hicle-speed signal will no longer be emitted. Im-         hook to prevent the lateral runout of front
mediately have it repaired.                               wheels.
5) Use only genuine SUBARU AT fluid in the                D Do not abruptly depress/release clutch
transmission.                                             pedal or accelerator pedal during tests even
                                                          when engine is operating at low speeds
E: FULL-TIME AWD MT MODELS                                since this may cause vehicle to jump off test
1. SPEEDOMETER TEST (Jack-up method)                      machine.
                                                          D Avoid abrupt braking after tests.
WARNING:
D Secure a rope or wire to the front towing               1) Position vehicle so that front wheels are
hook to prevent the lateral runout of front               placed between rollers of test machine.
wheels.                                                   2) Scribe alignment mark corresponding with
D Do not abruptly depress/release clutch                  centerline of rear wheels on floor.
pedal or accelerator pedal during tests even



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                             G8040BE1SGML



1-3     [G1E3]                    GENERAL INFORMATION
1. General Precautions


                                                         4. CHASSIS DYNAMOMETER TEST
                                                         WARNING:
                                                         D Do not abruptly depress/release clutch
                                                         pedal or accelerator pedal during tests.
                                                         D Avoid abrupt braking tests after tests.
                                                         1) Locate vehicle onto chassis dynamometer
                                                         tester.
                                                         2) Locate rear wheels onto free rollers.
                                                         3) Perform dynamic performance tests.
                                                         5. TIRE BALANCE TEST (ON-car machine)
                                         S1H0005A
                                                         CAUTION:
3) Back up vehicle so that centerline of free            D Perform tire balance tests after each tire
rollers are aligned with mark scribed in step 2          balance has been measured.
above.                                                   D Locate the vehicle so that its front and rear
4) Drive vehicle onto free rollers.                      sides are equal in height.
5) Perform speedometer tests.                            D Release parking brake.
                                                         D Manually rotate each tire and check for
3. BRAKE TEST                                            drag.
1) Drive vehicle for a distance of several kilo-         D Do not operate clutch and do not acceler-
meters (miles) to stabilize dragging force of vis-       ate the engine abruptly.
cous coupling.                                           D If error occurs due to engine operation, do
2) Place vehicle onto brake tester.                      not operate balance's motor.
                                                         1) Raise vehicle so that left and right wheels to
                                                         be checked clear the floor. Support wheels us-
                                                         ing pick-up stands.
                                                         2) Raise the other two wheels off the ground
                                                         and support with a safety stand.
                                                         3) Attach on-car machine to wheels to be
                                                         checked.




                                          S1H0006


3) Perform brake tests.
Effect of braking force on viscous coupling
torque:
    Approx. 245 N (25 kg, 55 lb)
NOTE:
                                                                                                 S1H0007A
If dragging force exceeds specifications,
check brake pad or brake shoe for dragging.
                                                         4) Drive wheel with engine and perform tire
Abnormalities related to the viscous torque of
                                                         balance tests.
viscous coupling unit may cause excessive
dragging force. At this point, raise vehicle so
that two front or rear wheels clear floor, remove
cause of abnormality and check wheel rotation.




                                                     4
                    G8040BE1SGML



                                 GENERAL INFORMATION                                     [G1E6]     1-3
                                                                                  1. General Precautions


6. TOWING
1) Loading vehicle onto dolly or flat-bed truck
CAUTION:
D Transport vehicle using a dolly or flat-bed
truck whenever possible.
D Move shift lever to "1st" position and ap-
ply parking brake.



                                                                                               S1H0009


                                                       3) Towing with front or rear wheels raised
                                                       CAUTION:
                                                       D Do not tow vehicle with only front or rear
                                                       wheels placed on towing dolly or flat-bed
                                                       truck. This may degrade viscous coupling
                                                       performance or cause vehicle to jump off
                                       S1H0008A        dolly or truck.
2) Towing with a rope
CAUTION:
D Use a rope only when power train and all
wheels are operating properly.
D The ignition switch should be in the
"ACC" position. Never have the ignition
switch on "LOCK" while the vehicle is being
towed because steering will not be possible,
since the direction of the wheels will be
locked.
D Put the transmission in neutral.                                                            S1H0010A
D Never use the tie down hooks for towing.
D Remember that brake booster and power                D Do not tow vehicle with rear wheels raised
steering will not work when engine is "OFF".           under any circumstances since this will
You will have to use greater effort for the            damage bumper.
brake pedal and steering wheel.
D Before towing, check transmission oil and
differential oil levels and top up to the speci-
fied level if necessary.




                                                   5
                            G8040BE1SGML



1-3     [G1F1]                  GENERAL INFORMATION
1. General Precautions




                                        S1H0011                                              S1H0013A


D Do not tow vehicle with front wheels
                                                       2. TOWING
raised under any circumstances since this
will damage bumper.                                    1) Loading vehicle onto dolly or flat-bed truck
                                                       CAUTION:
                                                       D Transport vehicle using a dolly or flat-bed
                                                       truck whenever possible.
                                                       D Place the selector lever in "P" position and
                                                       apply the parking brake.




                                        S1H0012



F: FULL TIME AWD AT MODELS
1. BEFORE CHECKING OR SERVICING
CARS WITH THE FRONT WHEELS RAISED                                                            S1H0008A
OR ON ROLLERS (BRAKE TESTER, CHAS-
SIS DYNAMOMETER, ETC.)                                 2) Towing with a rope
CAUTION:                                               CAUTION:
Ensure that the FWD pilot light is on. If the          D Tow vehicle with a rope only when power
car is left in the AWD mode, it will surge             train and all wheels are operating properly.
abruptly when the wheels turn, possibly                D Put a spare fuse inside the FWD connector
damaging the transfer clutch.                          and never exceed 30 km/h (19 MPH). Also, do
Always set the car in the FWD mode.                    not tow for more than 50 km (31 miles).
To set the car in the FWD mode, disconnect the         D Place the selector lever in "N" position.
AWD circuit by inserting a fuse in the FWD con-        D The ignition switch should be in the
nector inside main fuse box. Also chock the rear       "ACC" position while the vehicle is being
wheels firmly.                                         towed.
                                                       D Never use the tie down hooks for towing.
                                                       D Remember that brake booster and power
                                                       steering will not work when the engine is




                                                   6
                    G8040BE1SGML



                                 GENERAL INFORMATION          [G1F2]     1-3
                                                       1. General Precautions


"OFF". You will have to use greater effort for
the brake pedal and steering wheel.
D Before towing, check transmission oil and
differential oil levels and top up to the speci-
fied level if necessary.




                                        S1H0009


3) Towing with front or rear wheels raised
CAUTION:
Do not tow vehicle with front or rear wheels
raised under any circumstances since this
will damage bumper.




                                        S1H0016




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