ECU SUBARU FORESTER 2004 Service Repair Manual

FUJI HEAVY INDUSTRIES LTD. G8080GE7
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
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, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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 genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB

EI-23
EXTERIOR/INTERIOR TRIM
Front Bumper
5. Front Bumper
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Loosen the two clips to remove the mud guard and
front under cover.
3) Turn over the mud guard, and remove two inside
clips which securing front bumper to fender.
4) Turn over the mud guard, and disconnect the fog
light connector before removing a bolt and clip
which installed to under side of fog light hole.5) Remove the front grille and front grille side.

6) Remove the eight clips, and pull out the bumper
slightly.
7) Remove the E/A FORM from bumper beam.
E/A FORM may easily break. Do not apply exces-
sive force to it during removal.
8) Remove the bumper beam.
9) Remove the eight bolts to disassemble the front
bumper beam.
EI-00031
EI-00032
EI-00033
EI-00034
EI-00035
EI-00036
EI-00095

EI-43
EXTERIOR/INTERIOR TRIM
Upper Inner Trim
17.Upper Inner Trim
A: REMOVAL
1) Remove the lower inner trim. MOVAL, Lower Inner Trim.>
2) Remove the front molding (A).
3) Remove the front pillar upper trim (B).
4) Detach the front seat belt shoulder anchor, then
remove the center pillar upper trim (C).
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing the center pillar upper trim and front
pillar upper trim, be sure to set the front molding as
shown in the figure.
(D) Clip
(A) Outside
(B) Inside
(C) Molding
(D) Weather strip
(E) Trim
(F) Body
EI-00105
(A)
(B)(C)
: (D)
EI-00106
(A)
(C)(B)
(E)
(F) (D)

EI-44
EXTERIOR/INTERIOR TRIM
Lower Inner Trim
18.Lower Inner Trim
A: REMOVAL
1) Remove the side sill front cover (A).
2) Remove the rear seat cushion REMOVAL, Rear Seat.>, then remove side sill rear
cover (B).
3) Remove the center pillar lower trim (C).
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
(D) Clip
EI-00072
(A)(C)(B)
: (D)

EI-45
EXTERIOR/INTERIOR TRIM
Rear Quarter Trim
19.Rear Quarter Trim
A: REMOVAL
1) Remove the rear seat. AL, Rear Seat.>
2) Remove the side sill rear cover.
3) Remove the rear rail trim (A).
4) Remove the strut cap.
5) Remove the shoulder anchor of rear seat belt.
6) Loosen the screws and clips to remove rear
quarter upper trim (B).
7) Remove the rear skirt trim (C).
8) Loosen the screws and clips to remove rear
quarter lower trim (D).
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing the rear quarter upper trim, be sure
to set the rear molding as shown in the figure.
(E) Clip
(F) Hook
EI-00073
(D)(A)
(B)
(C)
: (E): (F)
(A) Outside
(B) Inside
(C) Molding
(D) Weather strip
(E) Trim
(F) Body
EI-00106
(A)
(C)(B)
(E)
(F) (D)

EI-49
EXTERIOR/INTERIOR TRIM
Floor Mat
23.Floor Mat
A: REMOVAL
1) Remove the front seats. AL, Front Seat.>
2) Remove the rear seat cushion. REMOVAL, Rear Seat.>
3) Remove the console box. sole Box.>
4) Remove the side sill front cover, side sill rear
cover and center pillar lower trim. REMOVAL, Lower Inner Trim.>
5) Remove the footrest or clips from floor mat.
6) Remove the mat hook.
7) Remove the mat from toe board area.
8) Remove the mat from rear heater duct.
9) Roll the mat, and then take it out of opened rear
door.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
 Secure the mat firmly with hook and Velcro tape.
 Insert the mat edge firmly into the groove of side
sill cover.
(A) Vehicle front
(1) Floor mat
EI-00079
(A)(1)

FUJI HEAVY INDUSTRIES LTD. G8080GE7
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
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, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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 genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB

EB-19
EXTERIOR BODY PANEL
Rear Gate Panel
C: DISPOSAL
1. REAR GATE DAMPER STAY
CAUTION:
Gas is colorless, odorless and harmless. How-
ever, gas pressure may spray cutting powder or
oil. Be sure to wear dust-resistant goggles.
1) Cover with a vinyl case as shown in the figure.
NOTE:
Prevent the vinyl case from being caught by drill
cutting edge.
2) Lift the body-side slightly with piston rods fully
extended, and secure the body side on vise stand.
Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at
a point 10 to 200 mm (0.39 to 7.87 in) from the door
side, and bleed the rear gate damper stay com-
pletely.
(1) Rear gate damper stay
(2) Vinyl sack
(1) Body-side
(2) Door-side
(3) 190 mm (7.48 in)
(4) 10 mm (0.39 in)
(5) Piston rod
(6) Cylinder
(7) Portion to be drilled
(1)
(2)
EB-00031
(3) (4)
(1)
(5)
(6)(7)(2)
EB-00032

FUJI HEAVY INDUSTRIES LTD. G8080GE7
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
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, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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 genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB

CC-4
CRUISE CONTROL SYSTEM
General Description
B: CAUTION
 Before disassembling or reassembling parts, al-
ways disconnect the battery ground cable. When re-
pairing the radio, control module and other parts with
memory functions, make note of the memory before
disconnecting the battery ground cable. All memory
will be erased.
 Reassemble parts in the reverse order of disas-
sembly unless otherwise indicated.
 Adjust parts to specifications specified in this man-
ual.
 Connect the connectors and hoses securely dur-
ing reassembly.
 After reassembly, ensure functional parts operate
properly.
C: PREPARATION TOOL
TOOL NAME REMARKS
Circuit Tester Used for measuring resis-
tance and voltage.