SUBARU FORESTER 2004 Service Repair Manual

GW-21
GLASS/WINDOW/MIRROR
Front Regulator and Motor Assembly
10.Front Regulator and Motor
Assembly
A: REMOVAL
1) Remove the door glass. <Ref. to GW-17, RE-
MOVAL, Front Door Glass.>
2) Loosen the nuts to remove rear sash.
3) Disconnect the motor connector.
4) Loosen the four bolts and two nuts to remove
regulator assembly.
5) Loosen the screw to remove motor assembly.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the front door glass. <Ref. to GW-18, AD-
JUSTMENT, Front Door Glass.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to GW-3, FRONT DOOR GLASS,
COMPONENT, General Description.>
C: INSPECTION
1) Make sure that the power window motor rotates
properly when battery voltage is applied to the ter-
minals of motor connector.
2) Change polarity of battery connections to termi-
nals to ensure that the motor rotates in reverse di-
rection.
GW-00027
GW-00028
GW-00029

GW-22
GLASS/WINDOW/MIRROR
Rear Door Glass
11.Rear Door Glass
A: REMOVAL
1) Remove the rear door trim. <Ref. to EI-36, RE-
MOVAL, Rear Door Trim.>
2) Remove the front speaker. <Ref. to ET-6, RE-
MOVAL, Front Speaker.>
3) Remove the sealing cover. <Ref. to EB-16, RE-
MOVAL, Rear Sealing Cover.>
4) Remove the stabilizer.
5) Remove the door weather strip.6) Loosen the two screws to remove the weather
strip outer.
7) Operate the power window switch to remove glass
as shown in the figure, and then remove two nuts.
8) Take out the door glass.
CAUTION:
Avoid impact and damage to the glass.
GW-00030
GW-00057
GW-00032
GW-00031

GW-23
GLASS/WINDOW/MIRROR
Rear Door Glass
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Make sure that the glass stay is placed securely
in sash.
2) Adjust the rear door glass. <Ref. to GW-23, AD-
JUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to GW-4, REAR DOOR GLASS,
COMPONENT, General Description.>
C: ADJUSTMENT
NOTE:
The rear door glass, as a rule, should be adjusted in
the same manner as front glass, although they are
different in dimension. Special notes for the rear
glass are given below.
1) Adjust the glass position using the following di-
mensions as a guide line. (Clearance between up-
per side and lower side is within 1.5 mm (0.059 in).)
NOTE:
 If the dimensions are smaller than the given di-
mensions, glass may get caught in weather strip
during lifting/lowering operation. In the worst case, it
may cause the glass not to be opened fully.
 After adjustment, move the glass up and down to
check whether it is caught.2) Adjust the crimp of glass using the following di-
mensions as a guide line.
NOTE:
 If the crimp of rear glass is higher than neces-
sary, glass may get caught in weather strip of cen-
ter pillar corner, resulting in early wear of weather
strip. Be careful when adjusting.
 After adjustment, move the glass up and down to
check whether it is caught.
(1) 12±1 mm (0.472±0.039 in)
AA
A-A
(1)
(1)
GW-00067
(1) 3.5±0.8 mm (0.137±0.031 in)
(2) 9.5±1 mm (0.374±0.039 in)
A
A
(1)
(2)
GW-00068

GW-24
GLASS/WINDOW/MIRROR
Rear Regulator and Motor Assembly
12.Rear Regulator and Motor As-
sembly
A: REMOVAL
1) Remove the door glass. <Ref. to GW-22, RE-
MOVAL, Rear Door Glass.>
2) Remove the front sash.
3) Disconnect the motor connector.
4) Loosen the four bolts and two nuts to remove
regulator assembly.
5) Loosen the screws to remove motor assembly.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the rear door glass. <Ref. to GW-23, AD-
JUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to GW-4, REAR DOOR GLASS,
COMPONENT, General Description.>
C: INSPECTION
1) Make sure that the power window motor rotates
properly when battery voltage is applied to the ter-
minals of motor connector.
2) Change polarity of battery connections to the ter-
minals to ensure that the motor rotates in reverse
direction.
GW-00035
GW-00036

GW-25
GLASS/WINDOW/MIRROR
Windshield Glass
13.Windshield Glass
A: REMOVAL
1. USING WINDSHIELD KNIFE
1) Remove the cowl panel. <Ref. to EI-32, REMOV-
AL, Cowl Panel.>
2) Remove the glass molding.
3) Tape the body side of the circumference of wind-
shield glass for protection.
4) Apply sufficient amount of soapy water to the ad-
hesive layer.
5) Insert the windshield knife into the adhesive lay-
er.
6) While holding the knife edge and windshield glass
edge at a right angle, move the windshield knife in
parallel to the windshield glass edge along face and
edge of windshield glass to cut the adhesive layer.
NOTE:
 Do not twist the windshield knife.
 Cutting of adhesive layer shall be started with
wider gap between windshield glass and body.
 Because the matching pins are bonded to cor-
ners of glass, use piano wire to cut the pin.
2. USING PIANO WIRE
1) Remove the cowl panel. <Ref. to EI-32, REMOV-
AL, Cowl Panel.>
2) Remove the roof molding and upper front mold-
ing.
3) Tape the body side of the circumference of wind-
shield glass for protection.
4) Make a hole in the adhesive layer using a drill or
knife.
5) Pass the piano wire through the hole, and attach
securely both the wire ends to pieces of wood.
6) Pull the wire ends alternately to cut off the adhe-
sive layer.
CAUTION:
 Do not tightly pull the piano wire against the
windshield glass edge.
 Be careful not to damage the interior and ex-
terior parts.
 When removal is made with area close to in-
strument panel, place a protection plate over it.
Pay particular attention to the removal.
 Do not cross piano wires. Otherwise they
may be cut.
(1) Putty knife
(2) Protective tape
(3) Matching pin
(4) Windshield glass knife
GW-00069 (1) (1)
(1)
(3)
(3)(2)
(4) A A-A
A
(1) Matching pin
(2) Body panel
(3) Glass
(1)(2)
(3)
A A
GW-00070
A-A
GW-00039

GW-26
GLASS/WINDOW/MIRROR
Windshield Glass
B: INSTALLATION
1) Clean the external circumference of windshield
glass with alcohol or white gasoline.
2) Remove the adhesive layer on the body using
cutter knife to obtain smooth face 2 mm (0.08 in)
thick.
CAUTION:
Be careful not to damage the body and paint
surface.
3) Clean the body with alcohol or white gasoline to
remove thoroughly chips, dusts and dirts from body
face.4) Apply the dam rubber to back of glass.
5) Remove the backing of double-faced adhesive
tape, and then align the molding mark (B) to notch
(A). Attach the molding around the edge of glass,
and then press it evenly to fit.
(1) Adhesive
(2) 2 mm (0.08 in)
(3) Dam rubber
(4) Glass
(4) (2) (1)
(3)
GW-00071
(1) Matching pin
(2) Dam rubber
(3) Fastener
(4) 13 mm (0.512 in)
(1)
(2)(3) (4)
(4)
(4)
GW-00072
GW-00042

GW-27
GLASS/WINDOW/MIRROR
Windshield Glass
6) Apply primer to the adhesive layer of glass using
sponge.
Glass primer:
Dow Automotive
U-401 or U-402
7) Apply primer to the adhesive layer of body.
Painted surface primer:
Dow Automotive
U-413
NOTE:
 Primer once attached to the painted surface of
the body and internal trim is hard to wipe off. Mask
the circumference of such areas.
 Let the primer dry for about ten minutes before
installing the glass.
 Do not touch the surface coated with primer.
8) Cut off the cartridge nozzle tip and set it in seal-
ant gun as shown.9) Apply adhesive to the glass end surface as shown.
Adhesive:
Dow Automotive
ESSEX U-400 HV
10) Fit the matching pins using suction rubber cup
to install the windshield glass.
11) Lightly press the windshield glass for tight fit.
12) Make flush the adhesive surface jutted out us-
ing spatula.
13) After completion of all work, allow the vehicle to
stand for about 24 hours.
NOTE:
 When the door is opened/closed after glass is bond-
ed, always lower the door glass and then open/close it
carefully.
 Move the vehicle slowly.
 For minimum drying time and time the vehicle
must be left standing before driving after bonding,
follow instructions or instruction manual from the ad-
hesive manufacturer.
14) After curing of adhesive, pour water on external
surface of vehicle to check that there are no water
leaks.
NOTE:
When a vehicle is returned to the user, tell him or
her that the vehicle should not be subjected to
heavy impact for at least three days.
15) Install the cowl panel. <Ref. to EI-32, INSTAL-
LATION, Cowl Panel.>
(1) Application of primer
(2) Glass side
(3) Body side
(1) 10 — 13 mm (0.39 — 0.51 in)
(2) 13 mm (0.51 in)
(3) 10 mm (0.39 in)
(4) 15 mm (0.59 in)
(3)
(2)(1)
GW-00073
GW-00074
(1)(2)
(3)
(4)
GW-00045

GW-28
GLASS/WINDOW/MIRROR
Inner Rearview Mirror
14.Inner Rearview Mirror
A: REMOVAL
NOTE:
The spring cannot be reused. Prepare a new spring
before removal.
1) Turn the mirror base 90 degrees clockwise or
counterclockwise to remove it.
2) Remove the spring from mirror base.
CAUTION:
Be careful not to damage the mirror surface.
3) If the mirror base is damaged, remove the mirror
base using piano wire or spatula, etc.
CAUTION:
Be careful not to damage the windshield glass.
B: INSTALLATION
1) If removing the mirror base, remove the remain-
ing adhesive thoroughly, and then fit the mirror
base to mark on windshield glass to install.
Adhesive:
REPAIR KIT IN MR (Part No. 65029FC000)
2) Verify that the mirror base is adhered securely,
and then install the spring.
3) Install in the reverse order of removal.
C: INSPECTION
1) Check that the mirror is not damaged.
2) Check that the spring is not damaged.
GW-00046
GW-00047

GW-29
GLASS/WINDOW/MIRROR
Rear Gate Glass
15.Rear Gate Glass
A: REMOVAL
1) Remove the rear gate garnish. <Ref. to EB-20,
REMOVAL, Rear Gate Garnish Assembly.>
2) Remove the electrical connector from rear de-
fogger terminal.
3) Remove the glass in same procedure as for wind-
shield glass. <Ref. to GW-25, REMOVAL, Wind-
shield Glass.>
NOTE:
A matching pin is cemented to corners of the glass
on the compartment side. Use a piano wire when
cutting each pin.
B: INSTALLATION
1) Install a new rubber strip (A) by aligning it with
the end of the rear gate glass (B).2) Install the glass in same procedure as for wind-
shield glass.
3) About one hour after installation, conduct a leak test.
4) After completion of all work, allow the vehicle to
stand for about 24 hours.
NOTE:
 When the door is opened/closed after glass is bond-
ed, always lower the door glass and then open/close it
carefully.
 Move the vehicle slowly.
 For minimum drying time and time the vehicle
must be left standing before driving after bonding,
follow instructions or instruction manual from the
adhesive manufacturer.
 When a vehicle is returned to the user, tell him or
her that the vehicle should not be subjected to
heavy impact for at least three days.
5) Connect the rear defogger terminals.
6) Install the rear gate garnish. <Ref. to EB-20, IN-
STALLATION, Rear Gate Garnish Assembly.>
(1) Body panel
(2) Glass
(3) Matching pin
GW-00297
(3)
(3) (1)(2)
A-A A
A
GW-00049
(B)
(A)
A) Upper side
B) Left and right side
(1) Adhesive
(2) Strip rubber
(3) Glass
(4) Primer
(5) 12 mm (0.47 in)
(6) 14 mm (0.55 in)
(7) 10 — 13 mm (0.39 — 0.51 in)
(8) 8 mm (0.31 in)
(9) 12 mm (0.47 in)
GW-00075 (6)
(4)
(4)
(9)(8) (3)
(7)(7)(3) (2)
(2)(1)
(1)(5)
(5) (A)
(B)

GW-30
GLASS/WINDOW/MIRROR
Rear Window Defogger System
16.Rear Window Defogger System
A: WIRING DIAGRAM
1. REAR WINDOW DEFOGGER
<Ref. to WI-251, WIRING DIAGRAM, Rear Window Defogger System.>
B: INSPECTION
Symptom Repair order
Rear window defogger does not operate.(1) Fuse (M/B No. 1) (F/B No. 17)
(2) Rear defogger relay
(3) Rear defogger timer
(4) Defogger switch
(5) Rear defogger condenser
(6) Defogger wire
(7) Wiring harness