light 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

SR-9
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
Sunroof Switch
6. Sunroof Switch
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove the spot map light. MOVAL, Spot Map Light.>
3) Disconnect harness connectors and remove
sunroof switch (A).
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Check continuity between terminals when operat-
ing the switch.
Switch Terminal No. Standard value
Open 1 — 3 Less than 1 Ω
Close 3 — 4 More than 1 MΩ
SR-00017
(A)
21453
SR-00011

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-4
EXTERIOR/INTERIOR TRIM
General Description
5. FRONT BUMPER
(1) Bumper face (6) Upper beamTightening torque: N·m (kgf-m, ft-lb)
(2) E/A form (7) Lower beamT1: 32 (3.3, 24)
(3) Fog light (8) Lower beam reinforcementT2: 69 (7.0, 51)
(4) Side bracket (9) Clip
(5) Main beam (10) Slider side front
EI-00751
(1) (2)
(3) (4) (6)
(5)
(7)(8)
T1
T2
T1 T2
(9)
(9)
(9)
(9)
(10)

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-26
EXTERIOR/INTERIOR TRIM
Front Bumper
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER
NOTE:
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be re-
stored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of
the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this point
to the customer and get an understanding about the matter. Repair methods are outlined below, based on a
classification of the extent of damage.
1) Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
2) Deep damage caused by scratching fences, etc.
A dent cannot be repaired but a whitened or swelled part can be removed.
Pro-
cess
No.Process name Job contents
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sand paper in a “feathering” motion.
3FinishResin section Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recom-
mended wax: NITTO KASEI Soft 99 TIRE WAX
BLACK, or equivalent.Perform either the same operation as for the
resin section or process No. 18 and subse-
quent operations in the “3)” section, depending
on the degree and nature of damage.
Polish the waxed area with a clean cloth after 5
to 10 minutes.
Pro-
cess
No.Process name Job contents
1 Cleaning Clean the damaged area with water.
2Removal of dam-
aged areaCut off protruding area, if any, due to collision, using a putty knife.
3 Sanding Grind the affected area with #100 to #500 sand paper.
4FinishResin section Coated section
Same as Process No. 3 in the “1)” section.Perform Process No. 12 and subsequent oper-
ations in the “3)” section.

EI-30
EXTERIOR/INTERIOR TRIM
Rear Bumper
6. Rear Bumper
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the bolts and clips.
3) Remove the clips from bumper and bracket.
4) Remove the rear combination light assemblies
from each side. Combination Light Assembly.>
5) Remove the two clips from each side.
6) Remove the floor box.7) Remove the rear skirt trim.
8) Remove the bolt to remove bracket from
bumper.
9) Loosen the four nuts to remove rear bumper.
10) Disengage the clips to remove bumper upper
beam.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
General Description.>
C: REPAIR
Refer to front bumper repair. MOVAL, Front Bumper.>
EI-00043
EI-00044
EI-00045
EI-00047
EI-00046
EI-00048

EI-34
EXTERIOR/INTERIOR TRIM
Side Garnish
10.Side Garnish
A: REMOVAL
1) Incise the edge of garnish using cutter, and then
remove the garnish with pulling towards you by
hands.
NOTE:
Remove the garnish carefully. Forced removal of
garnish may damage garnish and clips.
2) Adhere the masking tape around area where the
double-sided tape of side garnish was adhere.
3) Apply the solvent (SUMITOMO 3M 4000 or equiv-
alent) to the area where double-sided tape was ad-
hered.
NOTE:
 Wipe off immediately when the solvent is touched
on the garnish surface.
 Do not use the solvent to the body which repaired
with lacquer paint.
4) Cover the area where the solvent applied using
plastic wrap, and then heat the double-sided tape
was adhered for 5 to 15 minutes in 40 to 60°C (104
to 140°F) using heat lamp.
5) Remove the double-sided tape of side garnish
side tape by following above step 3) and 4).
NOTE:
When the double-sided tape is not removed com-
pletely using above steps, use the scraper.
B: INSTALLATION
1) Apply the PRIMER (SUMITOMO 3M K-500 or
equivalent) widely to the slightly larger area where
double-sided tape was adhered, and then adhere
the double-sided tape (SUMITOMO 3M 5305 or
equivalent).
NOTE:
Use 5 mm (0.2 in) width and 1 mm (0.04 in) thick-
ness double-sided tape.
2) Heat the vehicle body to 40 to 60°C (104 to
140°F) and garnish to 20 to 30°C (68 to 86°F) using
heat lamp.
3) Remove the double-sided tape backing sheet, and
then align the clips to vehicle body holes. Press and
install the side garnish applying 69 — 98 N (7 — 10
kgf, 15 — 22 lbf) by the hands, using care to avoid air
entering.
NOTE:
 To keep the adhesion, do not wash the vehicle
within 24 hours.
 After the adhesion, use care not to move the side
garnish up and down.
C: INSPECTION
 Check the side garnish is not damaged or
cracked.
 Check the clips are not broken.
(1) Double-sided tape
(2) Front side
EI-00109
(1)
(2)
EI-00110
(1)
(2)

EI-47
EXTERIOR/INTERIOR TRIM
Roof Trim
21.Roof Trim
A: REMOVAL
CAUTION:
When removing the clip, use great care not to
damage the roof trim.
1) Disconnect the ground cable from battery.
2) Remove the over head console. (Sunroof model)

3) Remove the room light. AL, Room Light.>
4) Remove the sun visor and hook or both sides.

5) Remove the assist grip cap to remove assist grip
(A).
6) Remove the upper inner trim. MOVAL, Upper Inner Trim.>
7) Remove the rear quarter upper trim shown in the fig-
ure. Trim.>
(1) Remove the rear rail trim (A).
(2) Remove the rear quarter upper trim (B) of
both sides.8) Remove the clips, and then remove the roof trim.
B: INSTALLATION
Install in the reverse order of removal.
(C) Clip
EI-00075
(A)
EI-00076
(A)
(B)
: (C)EI-00077

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