dimensions SUBARU FORESTER 1999 Service Repair Manual

3. Datum Dimensions
Use a tram tracking gauge to measure all dimen-
sions. If a measuring tape is used, be extremely
careful because it tends to deflect or twist, which
results in a false reading.
G5M0122
NOTE:
IA suffix character ªRº or ªLº refers to the right or
the left.
IAll dimensions refer to the distance between the
centers of holes measured in a straight line.
IEach dimension indicates a projected dimension
between hole centers.
15
[S300]5-1SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions

A: FRONT STRUCTURE
S5M0137A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) R to (1) 851 (33.50) (10) R to (8) R 388 (15.28)
(11) L to (1) 912 (35.91) (10) L to (8) L 388 (15.28)
(11) R to (2) 960 (37.80) (11) L to (9) R 658 (25.91)
(11) L to (2) 864 (34.02) (11) R to (9) L 658 (25.91)
(11) R to (9) R 391 (15.39) (9) R to (9) L 965 (37.99)
(11) L to (9) L 391 (15.39) (11) L to (6) R 1,058 (41.65)
(11) R to (6) R 924 (36.38) (11) R to (6) L 1,058 (41.65)
(11) L to (6) L 924 (36.38) (6) R to (6) L 914 (35.98)
(11) R to (3) R 891 (35.08) (6) R to (10) L 1,549 (60.98)
(11) L to (3) L 891 (35.08) (6) L to (10) R 1,549 (60.98)
(10) R to (3) R 915 (36.02) (8) R to (3) R 528 (20.79)
(10) L to (3) L 915 (36.02) (8) L to (3) L 528 (20.79)
(10) R to (10) L 1,374 (54.09) (10) L to (3) R 1,636 (64.41)
(3) R to (3) L 1,338 (52.68) (8) R to (8) L 1,396 (54.96)
(5) R to (5) L 924 (36.38) (8) R to (10) L 1,438 (56.61)
(4) R to (4) L 1,296 (51.02) (8) L to (10) R 1,438 (56.61)
(5) R to (4) L 1,167 (45.94) (3) R to (8) L 1,465 (57.68)
(5) L to (4) R 1,167 (45.94) (3) L to (8) R 1,465 (57.68)
(60) R to (13) R 1,174 (46.22) (7) R to (7) L 860 (33.86)
(60) L to (13) L 1,174 (46.22) (7) R to (6) L 982 (38.66)
(60) R to (14) R 1,076 (42.36) (7) L to (6) R 982 (38.66)
(60) L to (14) L 1,076 (42.36) (7) R to (10) L 1,301 (51.22)
(10) R to (3) L 1,636 (64.41) (7) L to (10) R 1,301 (51.22)
16
5-1[S3A0]SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions

B: CENTER STRUCTURE
S5M0138A
17
[S3B0]5-1SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions

C: DOORS AND PASSENGER COMPARTMENT
S5M0139A
18
5-1[S3C0]SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions

Unit: mm (in)
Point to point Dimension Point to point Dimension
(14) L to (18) L 1,454 (57.24) (16) L to (64) L 860 (33.86)
(14) R to (18) R 1,454 (57.24) (16) R to (64) R 860 (33.86)
(13) L to (64) L 944 (37.17) (20) L to (23) L 845 (33.27)
(13) R to (64) R 944 (37.17) (20) R to (23) R 845 (33.27)
(20) L to (24) L 660 (25.98) (19) L to (23) L 885 (34.84)
(20) R to (24) R 660 (25.98) (19) R to (23) R 885 (34.84)
(20) L to (36) 1,484 (58.43) (11) L to (67) R 1,170 (46.06)
(20) R to (37) 1,487 (58.54) (11) R to (67) L 1,170 (46.06)
(42) L to (44) L 769 (30.28) (41) to (38) 1,518 (59.76)
(42) R to (44) R 769 (30.28) (41) to (39) R 1,581 (62.24)
(11) R to (12) 920 (36.22) (41) to (39) L 1,581 (62.24)
(11) L to (12) 920 (36.22) (41) to (40) R 1,499 (59.02)
(67) R to (67) L 1,045 (41.14) (41) to (40) L 1,499 (59.02)
(11) R to (67) R 1,040 (40.94) (41) to (15) R 1,186 (46.69)
(11) L to (67) L 1,040 (49.94) (41) to (15) L 1,186 (46.69)
(12) to (67) L 503 (19.80) (41) to (22) R 733 (28.86)
(12) to (67) R 503 (19.80) (41) to (22) L 733 (28.86)
(12) to (10) L 1,027 (40.43) (41) to (26) R 1,568 (61.73)
(12) to (10) R 1,027 (40.43) (41) to (26) L 1,568 (61.73)
(21) R to (21) L 1,322 (52.05) (41) to (25) 1,211 (47.68)
(15) R to (15) L 1,452 (57.17) (41) to (12) 1,299 (51.14)
(22) R to (22) L 1,452 (57.17) (41) to (21) R 962 (37.87)
(39) R to (39) L 1,392 (54.80) (41) to (21) L 962 (37.87)
(40) R to (40) L 1,402 (55.20) (41) to (17) R 1,333 (52.48)
(11) L to (17) R 1,149 (45.24) (41) to (17) L 1,333 (52.48)
(11) R to (17) L 1,149 (45.24)
19
[S3C0]5-1SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions

D: LUGGAGE COMPARTMENT
S5M0140A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(45) to (48) L 913 (35.94) (41) to (65) R 1,105 (43.50)
(45) to (48) R 913 (35.94) (41) to (65)L 1,105 (43.50)
(45) to (47) L 876 (34.49) (41) to (45) 1,570 (61.81)
(45) to (47) R 876 (34.49) (41) to (43) R 1,436 (56.54)
(47) R to (47) L 1,426 (56.14) (41) to (43) L 1,436 (56.54)
(49)R to (49) L 1,478 (58.19) (41) to (48) L 1,576 (62.05)
(34) R to (34) L 945 (37.20) (41) to (48) R 1,576 (62.05)
(48) R to (46) R 992 (39.06) (65) R to (65) L 1,268 (49.92)
(48) L to (46) L 992 (39.06) (17) R to (76) 627 (24.68)
(70) R to (70) L 1,218 (47.95) (17) L to (76) 680 (26.77)
(61) R to (75) R 448 (17.64) (72) R to (72) L 1,118 (44.02)
(61) L to (75) L 448 (17.64) (74) R to (75) R 480 (18.90)
(17) R to (75) R 705 (27.76) (74) L to (75) L 480 (18.90)
(17) L to (75) L 705 (27.76) (17) R to (73) 518 (20.39)
(45) to (71) 913 (35.94) (17) L to (73) 476 (18.74)
20
5-1[S3D0]SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions

4. Datum Points and Dimensions Concerning On-Board Aiming
Adjustment
If headlight aiming is misaligned due to a damaged body panel, repair headlight mating surface using body
and headlight datum points as a guide.
NOTE:
It is recommended to conduct on-board aiming adjustment with headlights turned OFF. If turned ON dur-
ing the adjustment, the duration should be within two minutes.
S5M0141A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) to (A) 890.6 (35.06) (11) to (C) 1,087.7 (42.82)
(11) to (B) 913.4 (35.96) (11) to (D) 1,023.7 (40.30)
21
[S400]5-1SPECIFICATIONS AND SERVICE DATA
4. Datum Points and Dimensions Concerning On-Board Aiming Adjustment

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

5. REAR DOOR GLASS
Alignment of rear door glass is basically the same as for the front door glass. Due to slight difference in
adjustment dimensions for fore-aft, up-down, and in-out alignments, key points for rear door adjustment are
described.
S5M0202B
23
[W2B5]5-2SERVICE PROCEDURE
2. Door