SUBARU FORESTER 2004 Service Repair Manual

BS-5
BODY STRUCTURE
Datum Points
(18) Front weather strip attaching hole
5.2 mm (0.20 in) dia. (Symmetri-
cal)(31) Harness attaching hole 7 mm
(0.28 in) dia. (Symmetrical)(45) Combination light attaching hole
9.5 mm (0.37 in) dia. (Symmetri-
cal)
(41) Harness attaching hole 7.5 mm
(0.30 in) dia.
(19) Trim attaching hole 7 mm (0.28 in)
dia. (Symmetrical)(46) Combination light attaching hole 7
mm (0.28 in) dia. (Symmetrical)
(42) Bumper beam attaching hole 12
mm (0.47 in) dia.
(24) Trim attaching hole 7 mm (0.28 in)
dia. (Symmetrical)(47) Combination light attaching hole
8×15 mm (0.31×0.59 in) (Symmet-
rical) (43) Striker gauge hole 5 mm (0.20 in)
dia. (Symmetrical)
(27) Front pillar gauge hole 12 mm
(0.47 in) dia. (Symmetrical)
(44) Harness attaching hole 7×7 mm
(0.28×0.28 in) dia. (Symmetrical)(48) Bumper bracket attaching hole 7
mm (0.28 in) dia. (Symmetrical)
(28) Insulator attaching hole 8 mm
(0.31 in) dia. (Symmetrical)
(29) Trim attaching hole 8.5 mm (0.33
in) dia. (Symmetrical)
BS-00002(48) (44)
(47)
(43)
(42)
(48)
(47)
(46)
(45)
(29)
(28)
(18)
(27)
(31)
(43)(41)
(44)
(24)
(19)
(18)
(45)
(46)

BS-6
BODY STRUCTURE
Datum Points
(12) Front strut attaching hole 9.5 mm
(0.37 in) dia. (Symmetrical)(56) Transverse link attaching hole 16
mm (0.63 in) dia. (Symmetrical)(62) Rear cross member gauge hole
16 mm (0.63 in) dia. (Symmetri-
cal)
(36) Rear strut attaching hole 10 mm
(0.39 in) dia. (Symmetrical)(57) Sub-frame attaching hole 16 mm
(0.63 in) dia. (Symmetrical)
(63) Rear cross member attaching hole
12 mm (0.47 in) dia. (Symmetri-
cal) (51) Radiator lower frame gauge hole
12 mm (0.47 in) dia. (Symmetri-
cal)(58) Transmission cross member
attaching hole 14 mm (0.55 in)
dia. (Symmetrical)
(64) Rear bumper beam attaching hole
RH 15 mm (0.57 in) dia. LH 19×15
mm (0.75×0.59 in) (52) Side frame gauge hole 20 mm
(0.79 in) dia. (Symmetrical)(59) Rear side frame gauge hole 15
mm (0.59 in) dia. (Symmetrical)
(53) Sub-frame attaching hole 16 mm
(0.63 in) dia. (Symmetrical)(60) Rear side frame gauge hole 18
mm (0.71 in) dia. (Symmetrical)(65) Front cross member attaching
hole 12.4 mm (0.49 in) dia. (Sym-
metrical)
(54) Front cross member attaching
hole 12.4 mm (0.49 in) dia. (Sym-
metrical)(61) Rear differential attaching hole 16
mm (0.63 in) dia. (Symmetrical)
(66) Rear cross member attaching hole
16 mm (0.63 in) dia. (Symmetri-
cal)
(55) Transverse link attaching hole 17
mm (0.69 in) dia. (Symmetrical)
BS-00003
(52)(53)(54)(65)(12)(55)(61)
(61)
(64)
(64)
(51)
(51)
(36)
(36)(66)
(66)(56)(57)(58)(59)(60)
(52)(53) (54)
(65)
(12)(55)
(56)(57)(58)
(59)
(60)(62)
(62)(63)
(63)

BS-7
BODY STRUCTURE
Datum Points
(1)
(2)
(2)
BS-00004BS-00005
(4)
(5) (3)
BS-00006
(6)
(7) (8)
BS-00007
(8)
BS-00008
(9)(10)
(12)
BS-00009
(11)
BS-00010
(13)
BS-00011
(14)
(16)(18)
(17)
(15)
(19)

BS-8
BODY STRUCTURE
Datum Points
BS-00014
(23)
(20)(21)
(22)
BS-00015 (24)
BS-00016
(25)
(26)
BS-00017
(27)
(28)
BS-00018
(29)
(30)
BS-00019
(34)
(31)
BS-00020
(32)
(33)(35)
(36)
BS-00021
(37)

BS-9
BODY STRUCTURE
Datum Points
(38)
(39)
(40)
BS-00022(41)(42)BS-00023
(43)
BS-00024
(44)
BS-00025
(46)
(45)
(47)
(48)
BS-00026
(51)(52)
(53)(54)
(65)
BS-00027
(56)
(58)
(57) (55)
BS-00028(59)
(60)BS-00029

BS-10
BODY STRUCTURE
Datum Points
(61)BS-00030
(66)
(62)(63)
BS-00031
(64)
BS-00032

BS-11
BODY STRUCTURE
Datum Dimensions
3. Datum Dimensions
A: MEASUREMENT
Refer to LOCATION for details on measurement
points.
NOTE:
 Using a tram tracking gauge, measure all dimen-
sions.
 When using a tape measure, carefully measure
dimensions without letting the tape measure sag or
twist.
 Measure the linear dimensions between cores of
holes.
 Suffixes “RH” and “LH” indicate right-hand and
left-hand.
 Measure at the center of the circle around the
outside of the body panel.
(1) Tram tracking gauge
(1) Datum point
(2) Body panel
(3) Outside
BS-00033
(1)
BS-00034
(1)
(3)
(2)

BS-12
BODY STRUCTURE
Datum Dimensions
1. CENTER STRUCTURE
*1: Standard line
*2: Side sill
*3: Upper surface
Unit: mm (in)
BS-00035
(54)(53)(52)
(55)(59)(57)(58)
(12)
(52)
(52)
(55)
(55)
(56)
(56)
(57)
(57)
(58)
(58)
(59)
(53)
(53)
(54)
(54)
(12)
(12)2
9(0.35)11(0.43)
77(3.03)
620(24.41)
910(35.83)
906(35.67)
856(33.70)
(62)(64)
(61)
(36)
1 13
694(27.32)
230(9.06)1070(42.13) 1270(50.00)
585(23.03)
500(19.69)
(61)
(61)
(64)
(64)
(63)
(63)
(62)
(62)
(36)
(36)
1136(44.72)
1221(48.07)
3
474(18.66)
621(24.45)
(51)
(51)860(33.86)1065(41.93)
(60)
(59)(60)
630(24.80)
(52)
(55)
(57)
(53)
(53)
(54)
924(36.38)917(36.10)
1209(47.60)
1005(39.57)
(61)(64)
(62)(59)(60)
1207(47.52)1124(44.25)
206(8.11)77(3.03)20(0.79) 14(0.55)
135(5.31)669(26.34)205(8.07)
356(14.02)
485(19.09)317(12.48)
329(12.95)
1110(43.70)920(36.22)920(36.22)838(32.99)529(20.83)780(30.71)776(30.55)
878(34.57)
1438(56.61)
1332(52.44)1205(47.44)
882(34.72)954(37.56)

BS-13
BODY STRUCTURE
Datum Dimensions
2. SUSPENSION CROSSMEMBER
*1: Standard line
*2: Side sill
Unit: mm (in)
BS-00036
(54)
(54)
(65)
(65)
(54)
(66)(63)2
75(2.95)
150(5.91) 2547(100.28)
860(33.86)
840(33.07)
(62)
(65)
1 1
(66)
(66)
(63)
(63)
(62)
(62)
920(36.22)
206(8.11)139(5.47)205(8.07)

BS-14
BODY STRUCTURE
Datum Dimensions
3. FRONT STRUCTURE
Unit: mm (in)
Point to point Dimension Point to point Dimension
(1) to (11) 822 (32.36) (7) LH to (15) LH 1,067 (42.01)
(2) RH to (11) 842 (33.15) (8) RH to (8) LH 921 (36.26)
(2) LH to (11) 875 (34.45) (9) RH to (9) LH 1,396 (54.96)
(3) RH to (3) LH 716 (28.19) (9) RH to (10) RH 398 (15.67)
(4) RH to (4) LH 978 (38.50) (9) LH to (10) LH 398 (15.67)
(5) RH to (5) LH 1,049 (41.30) (9) RH to (11) 767 (30.20)
(6) RH to (6) LH 1,341 (52.80) (9) LH to (11) 767 (30.20)
(6) RH to (9) RH 349 (13.74) (10) RH to (11) 722 (28.43)
(6) LH to (9) LH 349 (13.74) (10) LH to (11) 722 (28.43)
(6) RH to (11) 944 (37.17) (10) RH to (13) RH 907 (35.71)
(6) LH to (11) 944 (37.17) (10) LH to (13) LH 907 (35.71)
(7) RH to (14) RH 1,155 (45.47) (11) to (12) RH 565 (22.24)
(7) LH to (14) LH 1,155 (45.47) (11) to (12) LH 565 (22.24)
(7) RH to (15) RH 1,067 (42.01) (12) RH to (12) LH 1,065 (41.93)
(6) (6)
(5)
(5) (4)
(4)(1)
(3)(2) (9)(10)(13)
BS-00037
(2)
(13)
(11)(10)
(12)(14)
(15)
(3)
(9)
(8)
(7)
(8)
(12)