light SUBARU FORESTER 2004 Service Repair Manual

EB-12
EXTERIOR BODY PANEL
Front Door Panel
C: ADJUSTMENT
1) Using the ST, loosen the body-side bolts of upper
and lower hinges to align the position of front door
panel longitudinally and vertically.
ST 925610000 WRENCH
2) Loosen the door-side bolts of upper and lower
hinges to align the position of front door panel ver-
tically and laterally at the front end.
3) Loosen the screw (A) and lightly tap striker (B)
using a plastic hammer to adjust striker to align the
position of front door panel vertically and laterally at
the rear end.
CAUTION:
Do not use an impact wrench. Welding area on
the striker nut plate is easily broken.
EB-00016
ST
EB-00015
EB-00017
(B)(A)

EB-15
EXTERIOR BODY PANEL
Rear Door Panel
2) Loosen the door-side bolts of upper and lower hing-
es to align the position of rear door panel vertically and
laterally at front-end.
3) Loosen the screw (A) and lightly tap striker (B) using
plastic hammer to adjust striker to align the position of
rear door panel vertically and laterally at the rear end.
CAUTION:
Do not use an impact wrench. The welding area
on the striker nut plate is easily broken.
EB-00015
EB-00017
(B)(A)

EB-17
EXTERIOR BODY PANEL
Rear Gate Panel
8. Rear Gate Panel
A: REMOVAL
1. REAR GATE PANEL
1) Disconnect the ground cable from battery.
2) Open the rear gate.
3) Remove the rear gate trim. MOVAL, Rear Gate Trim.>
4) Remove the rear wiper motor. REMOVAL, Rear Wiper Motor.>
5) Remove the rear gate garnish assembly. EB-20, REMOVAL, Rear Gate Garnish Assembly.>
6) Remove the rear gate outer handle. 30, REMOVAL, Rear Gate Outer Handle.>
7) Remove the rear gate latch assembly. SL-31, REMOVAL, Rear Gate Latch Assembly.>
8) Disconnect the connectors of rear wiper, rear
defogger, and other lighting devices.
9) Disconnect the washer hose.
10) Remove the rubber duct (A) connection, and pull
out the harness and washer hose from rear gate.11) Using a support, support the rear gate and then
remove damper stay mounting bolts.
NOTE:
When the rear gate is released, it may hit and dam-
age the body. To prevent this, place a shop cloth be-
tween the body and gate.
12) Loosen the rear gate bolts to remove rear gate.
(A)
EB-00020
EB-00021
EB-00022
EB-00023

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

EB-20
EXTERIOR BODY PANEL
Rear Gate Garnish Assembly
9. Rear Gate Garnish Assembly
A: REMOVAL
1) Remove the rear gate panel trim. REMOVAL, Rear Gate Trim.>
2) Remove the rear wiper motor. REMOVAL, Rear Wiper Motor.>
3) Remove the seven frange nuts from inside of
rear gate panel.
4) Remove the license plate light assembly.
5) Close the gate, and then remove the rear gate
garnish assembly, pulling it forward by hand.
NOTE:
Be careful not to pull it strongly to avoid damage to
clips.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Check for serious scratches or cracks in rear gate
garnish assembly.
(1) Rear gate garnish ASSY
(2) Licence plate light bracket
(3) Licence plate light
EB-00033
(1)
(2)
(3)

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-10
CRUISE CONTROL SYSTEM
Stop and Brake Switch
6. Stop and Brake Switch
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from stop and brake
switch, and then remove the switch. 54, REMOVAL, Stop Light Switch.>
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the brake switch (A) and stop light switch
(B) resistance.
If NG, replace the stop and brake switch.
Switch Pedal Terminal No. Standard
BrakeReleased 1 and 4 Less than 1 Ω
Depressed 1 and 4 More than 1 MΩ
Stop lightReleased 2 and 3 More than 1 MΩ
Depressed 2 and 3 Less than 1 Ω
CC-00022
1234
(A)
(B)
3 2 14

CC-13
CRUISE CONTROL SYSTEM
Neutral Position Switch (MT model)
9. Neutral Position Switch (MT
model)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from neutral position
switch, and then remove the switch. 43, BACK-UP LIGHT AND NEUTRAL POSITION
SWITCH, REMOVAL, Switches and Harness.>
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the neutral position switch resistance.
 Non-turbo model
 Turbo model
If NG, replace the neutral position switch.
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 2Less than 1 Ω
Other positions More than 1 MΩ
Gear shift position Terminal No. Specified resistance
Neutral position
1 and 3Less than 1 Ω
Other positions More than 1 MΩ
MT-00110
1 2
MT-00111
1 2
3 4

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(H4SO)-7
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Cruise Control Module I/O Signal
4. Cruise Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Cruise indicator light 1  Battery voltage is present when main switch is turned ON.
 “0” volt is present when main switch is turned OFF.
Inhibitor switch (AT model) 4  Battery voltage is present when selector lever is other than “P” or “N” position.
 “0” volt is present when selector lever is set to “P” or “N” position.
Motor B 5  ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
 “0” volt is present when main switch is turned OFF.
Ground 6 —
Motor A 7  ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
 “0” volt is present when main switch is turned OFF.
RESUME/ACCEL switch 9  Battery voltage is present when command switch is turned to RESUME/ACCEL
position.
 “0” volt is present when command switch is released.
SET/COAST switch 10  Battery voltage is present when command switch is turned to SET/COAST
position.
 “0” volt is present when command switch is released.
Main power supply 11  Battery voltage is present when main power is turned ON.
 “0” volt is present when main power is turned OFF.
Ignition switch 12  Battery voltage is present when ignition switch is turned ON.
 “0” volt is present when ignition switch is turned OFF.
Motor C 13  ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
 “0” volt is present when main switch is turned OFF.
Motor clutch 14  ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
 “0” volt is present when vehicle is stopped.
Cruise control main switch 15  Battery voltage is present while pressing the main switch.
 “0” volt is present when main switch is released.
CC-00027
10
98
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