SUBARU FORESTER 1999 Service Repair Manual

1.
A:
NOTE:
This
details,
H5M0910A
13
[W1A0]5-2SER
1.

2. Door
A: REMOVAL AND INSTALLATION
1. DOOR ASSEMBLY
1) Remove front pillar lower trim [W5A1].> and disconnect connectors from body
harness.
B5M0726
2) Place a cloth or a wood block under door to
prevent damage, and support it with a jack.
3) Remove checker bolt.
Tightening torque:
32
±10 N´m (3.3±1.0 kg-m, 23.9±7.2 ft-lb)
S5M0183
4) Remove bolts (M8) securing upper and lower
hinges to door, and remove door from hinges.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
5) Remove hinges by loosening hinges mounting
bolt (M8) off of body.
Tightening torque:
29
±5 N´m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
CAUTION:
Work carefully to avoid damaging door.
G5M0385
6) Install in the reverse order of removal.
NOTE:
Apply grease to moving parts of door hinges.
14
5-2[W2A1]SERVICE PROCEDURE
2. Door

2. TRIM PANEL
CAUTION:
Be careful not to break clip by applying undue
force.
1) Front door trim:
(1) Remove gusset cover (A), power window
switch assembly (B) and pocket (C).
(2) Remove screws and then disengage the
clips.
(3) Detach trim panel and then disconnect con-
nector.
(4) Install in the reverse order of removal.
2) Rear door trim:
(1) Remove handle (E), pocket (F) and clips
(G).
(2) Remove screws and then disengage the
clips.
(3) Detach trim panel and then disconnect con-
nector.
(4) Install in the reverse order of removal.
S5M0383A
3. SEALING COVER
1) Remove trim panel.
2) Remove speaker, trim bracket, remote assem-
bly and disconnect connectors.
3) Remove sealer with a spatula.
CAUTION:
Be careful because cover may break if sealer is
removed forcefully.
G5M0391
4) Install in the reverse order of removal.
NOTE:
IConfirm that sealer is properly applied without
breaks. Then install sealing cover.
IWhen repairing or replacing sealing cover, use
ªCEMEDINE 5430Lº as sealer. It may be overlaid
on existing sealer.
Sealer:
CEMEDINE 5430L
CAUTION:
IAny breaks in sealer can cause water leak-
age or entry of air and dust. Be sure sealer is
applied in a continuous line.
IMake sure sealing cover bonded areas are
free from wrinkles or openings.
15
[W2A3]5-2SERVICE PROCEDURE
2. Door

4. CHECKER
1) Completely close door glass.
2) Remove trim panel.
3) Remove sealing cover.
4) Remove attaching bolt to body.
5) Loosen two nuts securing checker, and take out
checker through access hole in underside.
S5M0363A
6) Install in the reverse order of removal.
Tightening torque:
T1: 7.5
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4
ft-lb)
T2: 32
±10 N´m (3.3±1.0 kg-m, 23.9±7.2
ft-lb)
5. INNER REMOTE
1) Remove trim panel.
2) Remove sealing cover.
3) Disconnect joints of two rods.
4) Unlatch rod holder.
5) Remove inner remote assembly.
S5M0186
6) Install in the reverse order of removal.
NOTE:
If rear door is equipped with child safety lock,
check that child lock lever moves without dragging.
6. DOOR LATCH AND OUTER HANDLE
1) Completely close door glass.
2) Remove door trim panel.
3) Remove inner remote assembly.
4) Remove sealing cover around latch service
hole.
5) Remove latch and actuator assembly (A):
(1) Turn rod holder to disconnect joint between
key lock and rod.
(2) Turn rod holder to disconnect joint between
outer handle and rod.
(3) Turn rod holder to disconnect joint between
crank and rod.
(4) Loosen screws securing both latch and
actuator, then remove latch and actuator
assembly through service hole in bottom.
S5M0189A
(5) Install in the reverse order of removal.
Tightening torque (screw):
6.4
±2.0 N´m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
NOTE:
ICheck operation of each part.
ICheck each sliding part for proper lubrication.
CAUTION:
After installation, be sure lock mechanism
operates normally.
16
5-2[W2A4]SERVICE PROCEDURE
2. Door

6) Remove outer handle (B):
(1) Remove trim panel.
(2) Remove sealing cover.
(3) Loosen bolts securing outer handle and
then remove outer handle from outside.
CAUTION:
Be careful not to damage door.
S5M0189A
(4) Install in the reverse order of removal.
Tightening torque:
7.4
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
7. KEY LOCK
1) Remove trim panel.
2) Remove sealing cover.
3) Completely close door glass.
4) Remove outer handle.
5) Loosen spring securing key lock.
6) Remove key lock from outer handle.
7) Install in the reverse order of removal.
8. GUSSET
1) Be sure window is all the way down.
2) Remove gusset cover.
3) Remove trim panel.
4) Remove door rearview mirror.
5) Remove outer weatherstrip.
6) Remove sealing cover.
NOTE:
Be careful not to drop nuts inside the door.7) Remove bolts and nuts which secure gusset.
Tightening torque: Bolt
13
±3 N´m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
Tightening torque: Nut
7.4
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
S5M0190
8) Lift out gusset.
9) Install in the reverse order of removal.
B: ADJUSTMENT
1. DOOR ASSEMBLY
1) Using ST, loosen bolts securing upper and
lower hinges to body, and adjust fore-and-aft and
vertical alignment of door.
ST 925610000 DOOR HINGE WRENCH
B5M0933A
2) Loosen screw one complete rotation, and
adjust opening/closing direction of door using a
hammer covered with a cloth.
CAUTION:
Be careful not to damage striker.
Hinge tightening torque (body side):
29
±5 N´m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
Striker tightening torque:
18
±4 N´m (1.8±0.4 kg-m, 13.0±2.9 ft-lb)
17
[W2B1]5-2SERVICE PROCEDURE
2. Door

2. INNER REMOTE
1) Lock the door.
2) Loosen bolt (A).
3) Lower bell crank (B) and then tighten bolt (A).
S5M0191A
3. PROCEDURE CHART FOR ADJUSTING DOOR GLASS
H5M0912B
18
5-2[W2B2]SERVICE PROCEDURE
2. Door

4. FRONT DOOR GLASS
S5M0196B
19
[W2B4]5-2SERVICE PROCEDURE
2. Door

IDoor glass fit adjustment
Before adjusting door glass alignment, ensure
adjusting bolts for stabilizers, upper stoppers and
sashes are loose and glass is raised so that it is in
contact with upper and side weatherstrip.
1) Temporarily tighten one of the two rear sash
adjusting bolts, at midpoint of oblong hole on inner
panel.
2) Temporarily tighten regulator B channel at a
position slightly lower than midpoint of oblong hole
on inner panel.
3) Lower door glass 10 to 15 mm (0.39 to 0.59 in)
from fully closed position. While applying outward
pressure (load) to upper edge of glass above mid-
point of two outer stabilizers, push in inner stabi-
lizer to glass with 10±5 N (1.0±0.5 kg, 2.2±1.1 lb)
force, then secure it.
Load: F
Front door glass 44.1
±4.9 N (4.5±0.5 kg,
9.9
±1.1 lb)
Rear door glass 44.1
±4.9 N (4.5±0.5 kg,
9.9
±1.1 lb)
G5M0421
IRemedy for unequal dimensions,
between upper, lower and center pillar
sides
1) Close front door and raise door glass.
2) Check for unequal dimensions.
G5M0639
3) If glass tilts too far rearward, loosen adjusting
nut (3) (A) and adjust glass to be parallel with cen-
ter pillar, then after adjustment, tighten adjusting
nut (3).
Tightening torque:
7.4
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
S5M0197B
20
5-2[W2B4]SERVICE PROCEDURE
2. Door

IRemedy for improper glass-to-center
pillar clearance
1) Close front door and raise door glass.
2) Check for improper clearance.
S5M0198A
3) If clearance is improper, loosen adjusting nut
(2) (A), adjusting bolt (2) (B) and adjust glass to
center pillar.
S5M0199B
IRemedy for improper upper stop point
of door glass
1) Loosen front and rear sash stoppers.
2) Increase the upward travel of window glass up
to the position where upper edge just touches
weatherstrip surface with door closed.
G5M0511
3) After adjustment, temporarily tighten stoppers.
NOTE:
Make sure that each glass stopper is touching.
IRemedy for incorrect contact of door
glass to weatherstrip
1) Close front door and raise door glass.
2) If clearance is below specifications, loosen
adjusting bolt (2) and adjusting bolt (1).
3) If clearance is over specifications, tighten
adjusting bolt (2) and adjusting bolt (1).
S5M0200A
IFit adjustment
Door glass fit is adjusted by displacing the glass
front edge with a stabilizer.
NOTE:
Before adjusting glass fit, visually check to deter-
mine relative adjusting positions of retainer and
molding (on roof side) and glass surface.
1) Alternately adjust the two rear sash adjusting
bolts (2) until dimensions are obtained.
CAUTION:
Do not loosen the two adjusting nuts (2) at the
same time, as this moves sash fore and aft,
creating unequal glass-to-sash clearance. Dur-
ing adjustment, loosen only one nut and keep
the other tightened.
S5M0200A
21
[W2B4]5-2SERVICE PROCEDURE
2. Door

NOTE:
Always adjust the two rear sash adjusting bolts (2)
by the same amount. Do not adjust the adjusting
bolts with the sash bracket inclined toward the
inner panel, as this increases effort required to
operate the regulator.
S5M0201A
2) Adjust the front sash fit using the rear sash
adjustment procedure outlined in the former proce-
dure as a guide. The two adjusting bolts must be
adjusted by the same amount.
NOTE:
IFront and rear sash adjustment procedures are
basically the same; however, the amount of adjust-
ment is not always the same due to alignment dis-
persion of individual doors.
IAdjust front and rear sash fit, as equally as pos-
sible. Otherwise, effort required to operate regula-
tor may increase.
3) After adjusting front sash-to-glass fit, secure
front sash.
22
5-2[W2B4]SERVICE PROCEDURE
2. Door