SUBARU FORESTER 2004 Service Repair Manual

GW-31
GLASS/WINDOW/MIRROR
Rear Window Defogger
17.Rear Window Defogger
A: INSPECTION
CAUTION:
When wiping stain on glass off with cloth, use a
dry and soft cloth and move it in the direction of
heat wire extension to avoid damage to heat
wire.
1) Turn the ignition switch to ON.
2) Turn the defogger switch to ON.
3) Wrap the tips of tester pins with aluminum foil to
avoid damage to heat wire.
4) Measure the voltage at wire center with DC volt-
meter.
Standard voltage:
Approx. 6 V
NOTE:
 If the measured value is 12 volts, heat wire is
open between wire center and positive (+) end.
 If zero volt, heat wire is open between wire cen-
ter and ground. 5) Apply positive lead of voltmeter to positive terminal
of heat wire, and then move the negative lead along
the wire up to negative terminal end. If voltage chang-
es from zero to several volts during movement of
lead, heat wire is open at the voltage change point.
B: REPAIR
1) Clean the broken portion with alcohol or white
gasoline.
2) Mask both side of wire with thin film.
3) Apply conductive silver composition (DUPONT
No. 4817) to broken portion.
4) After repair, check the wire.
(1) Tester probe
(2) Tin foil
(3) Heat wire
(4) PRESS
(1) Center
Voltage Criteria
Approx. 6 V OK
Approx. 12 V or 0 V Broken
GW-00076
(2)(3) (4)
(1)
GW-00077
(1)
(1) Broken portion
(2) Masking thin film
(3) Broken wire
(4) Conductive silver composition (DUPONT No.
4817)
GW-00078
(2)(3)
(4)
(1)

GW-32
GLASS/WINDOW/MIRROR
Rear Quarter Glass
18.Rear Quarter Glass
A: REMOVAL
Remove the glass in the same procedure as for windshield glass. Glass.>
B: INSTALLATION
1) Cut off the nozzle tip as shown in the figure.2) Install the glass in the same procedure as for wind-
shield glass. Windshield Glass.>
3) After completion of all work, allow the vehicle to
stand for about 24 hours.
NOTE:
 When the door is opened/closed after glass is bond-
ed, always lower the door glass and then open/close it
carefully.
 Move the vehicle slowly.
 For minimum drying time and time the vehicle
must be left standing before driving after bonding,
follow instructions or instruction manual from the
adhesive manufacturer.
4) After curing of adhesive, pour water on external
surface of vehicle to check that there are no water
leaks.
(1) Molding (4) Locating pin (7) Weather strip
(2) Adhesive (5) Body (8) Rear door glass
(3) Interior trim (6) Cover C pillar
GW-00054
(1)
(1)(1) A
A-A
D
CB
D-D
B-BC-C
(2)
(2)(4)(4)
(3)
(3)
(7)
(8)(5)(2)
(2)
(3)(3)
(6)
(5)
(5)
(1) Molding
(2) Matching pin
(3) Adhesive
(4) 10 mm (0.39 in)
(5) 15 mm (0.59 in)
(6) 10 — 13 mm (0.39 — 0.51 in)
GW-00079
(4)
(5)
(6)(1)
(3)
(2)
(3)
(1)

GW-33
GLASS/WINDOW/MIRROR
Rear Quarter Glass
NOTE:
When a vehicle is returned to the user, tell him or her
that the vehicle should not be subjected to heavy im-
pact for at least three days.

GW-34
GLASS/WINDOW/MIRROR
Roof Window Glass
19.Roof Window Glass
A: REMOVAL

B: INSTALLATION

C: ADJUSTMENT

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

2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G8080GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4SO)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4DOTC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4DOTC 2.5)
IMMOBILIZER (DIAGNOSTIC) IM

BODY STRUCTURE
BS
Page
1. General Description ....................................................................................2
2. Datum Points...............................................................................................3
3. Datum Dimensions ....................................................................................11

BS-2
BODY STRUCTURE
General Description
1. General Description
A: PREPARATION TOOL
TOOL NAME REMARKS
Tram tracking gauge Used for measuring dimen-
sion.
Tape measure Used for measuring dimen-
sion.

BS-3
BODY STRUCTURE
Datum Points
2. Datum Points
A: LOCATION
NOTE:
 Datum points are specified for body repair.
 Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment
accuracy.
 Both right and left reference points are symmetrical.
BS-00001
(6)
(7)
(3)
(4)
(5)
(5)(4)
(2)
(1)(3)(2)(8)
(9)
(10)
(12)
(11)
(31)
(33)
(36)(13)
(29)
(34)(13)
(32)
(23)
(30)
(35)(38)(39)
(40)
(25)
(26)
(21)
(22)
(20)
(14)
(16)(17)
(15)
(10)(12)(9)
(6)
(7)(8)
(37)

BS-4
BODY STRUCTURE
Datum Points
(1) Radiator panel gauge hole 6 mm
(0.24 in) dia. (Vehicle center)(14) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)(31) Harness attaching hole 7 mm
(0.28 in) dia. (Symmetrical)
(2) Radiator attaching hole 12 mm
(0.47 in) dia.(15) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)(32) Trim attaching hole 8.5 mm (0.33
in) dia. (Symmetrical)
(3) Headlight attaching hole 7 mm
(0.28 in) dia. (Symmetrical)(16) Front door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)(33) Trim attaching hole 7 mm (0.28 in)
dia. (Symmetrical)
(4) Frame plate gauge hole 8 mm
(0.31 in) dia. (Symmetrical)(17) Front door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)(34) Harness attaching hole 7×7 mm
(0.28×0.28 in) (Symmetrical)
(5) Bumper beam attaching hole 11
mm (0.43 in) dia. (Symmetrical)(20) Front door switch attaching hole
4.1 mm (0.16 in) dia. (Symmetri-
cal)(35) Tonneau cover bracket attaching
hole 5.5 mm (0.22 in) dia. (Sym-
metrical)
(6) Fender attaching hole 7 mm (0.28
in) dia. (Symmetrical)
(21) Rear door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)(36) Rear strut attaching hole 10 mm
(0.39 in) (Symmetrical)
(7) Fender attaching hole 9 mm (0.35
in) dia. (Symmetrical)
(22) Rear door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)(37) Floor mat attaching hole 8 mm
(0.31 in) dia.
(8) Power steering tank attaching hole
RH ATF cooler pipe attaching hole
LH 9 mm (0.35 in) dia.(23) Front weather strip attaching hole
5.2 mm (0.20 in) dia. (Symmetri-
cal)(38) Trim attaching hole 9×9 mm
(0.35×0.35 in) (Symmetrical)
(9) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)(39) Trim attaching hole 8 mm (0.31 in)
dia. (Symmetrical)
(25) Rear weather strip attaching hole
5.2 mm (0.20 in) dia. (Symmetri-
cal) (10) Fender attaching hole 7 mm (0.28
in) dia. (Symmetrical)(40) Trim attaching hole 8 mm (0.31 in)
dia. (Symmetrical)
(11) Modular bracket gauge hole 8 mm
(0.31 in) dia. (Vehicle center)(26) Rear door switch attaching hole
4.1 mm (0.16 in) dia. (Symmetri-
cal)
(12) Front strut attaching hole 9.5 mm
(0.37 in) dia. (Symmetrical)
(29) Trim attaching hole 8.5 mm (0.33
in) dia. (Symmetrical)
(13) Front glass attaching hole LH
6.5×10.5 mm (0.26×0.41 in) RH
6.5×7 mm (0.26×0.28 in)(30) Pad attaching hole 5 mm (0.20 in)
dia. (Symmetrical)