ECU SUBARU FORESTER 2004 Service Service Manual

GW-18
GLASS/WINDOW/MIRROR
Front Door Glass
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Make sure that the glass stay is placed securely
in sash.
2) Adjust the front door glass. JUSTMENT, Front Door Glass.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. COMPONENT, General Description.> GW-2, FIXED GLASS, COMPONENT, General
Description.>
C: ADJUSTMENT
NOTE:
Before adjustment, ensure that all adjusting bolts of
stabilizer, upper stopper and sash are loose and
door glass is raised so that it is in contact with
weather strip.
1) Temporarily tighten one adjusting bolt on one side
of rear sash at the midpoint of slotted hole in the in-
ner panel.
2) Temporarily tighten the regulator B-channel in a
position at the top of slotted hole.
3) Lower the door glass 10 to 15 mm (0.39 to 0.59
in) from fully closed position. While applying out-
ward pressure of 45.0±5 N (4.6±0.5 kg, 11.0±1.1
lb) (F) to upper edge of glass above midpoint of two
outer stabilizers, press the inner stabilizer at pres-
sure of 25±5 N (2.5±0.5 kg, 5.5±1.1 lb) to the glass,
then secure it.4) For adjustment of clearance between front glass
and center pillar cover, loosen the nuts (A), and
move the rear sash back and forward until clear-
ance becomes the value shown. (Clearance be-
tween upper side and lower side is within 1.5 mm
(0.059 in).)
5) For adjustment of upper and lower ends of cen-
ter pillar, loosen the adjusting nut (A) of B-channel
(B).
(1) Full close
(2) Stabilizer
(3) 10 — 15 mm (0.39 — 0.59 in)
(1) F
(2)
A = A AA
(2)(3)
GW-00063
(1) 12±1 mm (0.472±0.039 in)
GW-00019
(A)
AA
A-A
(1)
(1)
GW-00064
GW-00021
(A)
(B)

GW-19
GLASS/WINDOW/MIRROR
Front Door Glass
6) Adjust so that the upper and lower ends of cen-
ter pillar are the same size.
7) For glass stroke adjustment, close the door, raise
glass until positional relationship between glass and
weather strip becomes as shown. And secure the
glass so that the upper stopper lightly touches the
glass holder.For preventing wind noise, adjust the glass at the
position where tip of gusset is raised up a little.
8) After stabilizer adjustment, carry out the glass
crimp adjustment. First, visually ensure positional
relationship between retainer & molding and glass
of the roof side, and then begin with rear sash ad-
justment. Adjust two adjusting bolts alternately step
by step to obtain dimensions shown below (cross-
section A).
NOTE:
If two nuts are loosened at the same time, sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
9) Make the same adjustment of two adjusting bolts
of rear sash.
(1) Narrow
(2) Wide
(3) Glass tilts too far rearward
(4) Glass tilts too far forward
(5) Raise B channel
(6) Lower B channel
(1) 3.5±0.8 mm (0.137±0.031 in)
(2) 9.5±1 mm (0.374±0.039 in)
GW-00139 (6) (5)
(4)
(1)(2) (1)
(2) (3)
A
A
(1)
(2)
GW-00066
(A) 0 — 1.5 mm (0 — 0.059 in)
(1) 3.5±0.8 mm (0.137±0.031 in)
(2) 9.5±1 mm (0.374±0.039 in)
GW-00024
A
A
(1)
(2)
GW-00066

GW-23
GLASS/WINDOW/MIRROR
Rear Door Glass
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Make sure that the glass stay is placed securely
in sash.
2) Adjust the rear door glass. JUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. COMPONENT, General Description.>
C: ADJUSTMENT
NOTE:
The rear door glass, as a rule, should be adjusted in
the same manner as front glass, although they are
different in dimension. Special notes for the rear
glass are given below.
1) Adjust the glass position using the following di-
mensions as a guide line. (Clearance between up-
per side and lower side is within 1.5 mm (0.059 in).)
NOTE:
 If the dimensions are smaller than the given di-
mensions, glass may get caught in weather strip
during lifting/lowering operation. In the worst case, it
may cause the glass not to be opened fully.
 After adjustment, move the glass up and down to
check whether it is caught.2) Adjust the crimp of glass using the following di-
mensions as a guide line.
NOTE:
 If the crimp of rear glass is higher than neces-
sary, glass may get caught in weather strip of cen-
ter pillar corner, resulting in early wear of weather
strip. Be careful when adjusting.
 After adjustment, move the glass up and down to
check whether it is caught.
(1) 12±1 mm (0.472±0.039 in)
AA
A-A
(1)
(1)
GW-00067
(1) 3.5±0.8 mm (0.137±0.031 in)
(2) 9.5±1 mm (0.374±0.039 in)
A
A
(1)
(2)
GW-00068

GW-25
GLASS/WINDOW/MIRROR
Windshield Glass
13.Windshield Glass
A: REMOVAL
1. USING WINDSHIELD KNIFE
1) Remove the cowl panel. AL, Cowl Panel.>
2) Remove the glass molding.
3) Tape the body side of the circumference of wind-
shield glass for protection.
4) Apply sufficient amount of soapy water to the ad-
hesive layer.
5) Insert the windshield knife into the adhesive lay-
er.
6) While holding the knife edge and windshield glass
edge at a right angle, move the windshield knife in
parallel to the windshield glass edge along face and
edge of windshield glass to cut the adhesive layer.
NOTE:
 Do not twist the windshield knife.
 Cutting of adhesive layer shall be started with
wider gap between windshield glass and body.
 Because the matching pins are bonded to cor-
ners of glass, use piano wire to cut the pin.
2. USING PIANO WIRE
1) Remove the cowl panel. AL, Cowl Panel.>
2) Remove the roof molding and upper front mold-
ing.
3) Tape the body side of the circumference of wind-
shield glass for protection.
4) Make a hole in the adhesive layer using a drill or
knife.
5) Pass the piano wire through the hole, and attach
securely both the wire ends to pieces of wood.
6) Pull the wire ends alternately to cut off the adhe-
sive layer.
CAUTION:
 Do not tightly pull the piano wire against the
windshield glass edge.
 Be careful not to damage the interior and ex-
terior parts.
 When removal is made with area close to in-
strument panel, place a protection plate over it.
Pay particular attention to the removal.
 Do not cross piano wires. Otherwise they
may be cut.
(1) Putty knife
(2) Protective tape
(3) Matching pin
(4) Windshield glass knife
GW-00069 (1) (1)
(1)
(3)
(3)(2)
(4) A A-A
A
(1) Matching pin
(2) Body panel
(3) Glass
(1)(2)
(3)
A A
GW-00070
A-A
GW-00039

GW-28
GLASS/WINDOW/MIRROR
Inner Rearview Mirror
14.Inner Rearview Mirror
A: REMOVAL
NOTE:
The spring cannot be reused. Prepare a new spring
before removal.
1) Turn the mirror base 90 degrees clockwise or
counterclockwise to remove it.
2) Remove the spring from mirror base.
CAUTION:
Be careful not to damage the mirror surface.
3) If the mirror base is damaged, remove the mirror
base using piano wire or spatula, etc.
CAUTION:
Be careful not to damage the windshield glass.
B: INSTALLATION
1) If removing the mirror base, remove the remain-
ing adhesive thoroughly, and then fit the mirror
base to mark on windshield glass to install.
Adhesive:
REPAIR KIT IN MR (Part No. 65029FC000)
2) Verify that the mirror base is adhered securely,
and then install the spring.
3) Install in the reverse order of removal.
C: INSPECTION
1) Check that the mirror is not damaged.
2) Check that the spring is not damaged.
GW-00046
GW-00047

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

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

IDI-2
INSTRUMENTATION/DRIVER INFO
General Description
1. General Description
A: SPECIFICATION
B: CAUTION
 Be careful not to damage meters and instrument panel.
 Be careful not to damage meter glasses.
 Make sure that electrical connector is connected securely.
 After installation, make sure that each meter operates normally.
 Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
 Do not apply excessive force to the printed circuit.
 Do not drop or otherwise apply impact.
C: PREPARATION TOOL
1. GENERAL TOOL
Combination meterSpeedometer Electric pulse type
Temperature gauge Cross coil type
Fuel gauge Cross coil type
Tachometer Electric pulse type
Turn signal indicator light 14 V — 2 W
Charge indicator light 14 V — 1.4 W
Oil pressure indicator light LED
ABS warning light 14 V — 1.4 W
Malfunction indicator light LED
HI-beam indicator light 14 V — 2 W
Door open warning light LED
Seat belt warning light LED
Brake fluid and parking brake warning
light14 V — 2 W
FWD indicator light LED
AIRBAG warning light LED
Meter illumination light 14 V — 3.4 W, 14 V — 2 W
AT OIL TEMP. warning light LED
LO indicator light LED
HOLD indicator light LED
Immobilizer indicator light LED
Rear differential oil temperature warn-
ing light14 V — 2 W
Cruise indicator light 14 V — 1.4 W
Rear fog light indicator light 14 V — 2 W
POWER indicator light 14 V — 1.4 W
Low fuel warning light LED
AT select lever position indicator light 14 V — 100 mA
LCD back light 14 V — 1.4 W
TOOL NAME REMARKS
Circuit tester Used for measuring resistance and voltage.

IDI-10
INSTRUMENTATION/DRIVER INFO
Combination Meter Assembly
3. Combination Meter Assem-
bly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Set the tilt steering at lowest position.
3) Remove the screws and detach meter visor.
4) Remove the screws of combination meter and pull
out the meter toward you.
5) Disconnect the connector in the upper area of
combination meter to remove meter.
CAUTION:
 Be careful not to damage the meter or instru-
ment panel.
 Pay particular attention to avoid damaging
the meter glass.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
 Make sure that electrical connector is connected
securely.
 Make sure that each meter operates normally.
IDI00001
IDI00002

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