SUBARU FORESTER 2004 Service Repair Manual

EXTERIOR BODY PANEL
EB
Page
1. General Description ....................................................................................2
2. Front Hood Panel ........................................................................................9
3. Front Fender Panel ...................................................................................10
4. Front Door Panel .......................................................................................11
5. Front Sealing Cover ..................................................................................13
6. Rear Door Panel .......................................................................................14
7. Rear Sealing Cover ...................................................................................16
8. Rear Gate Panel .......................................................................................17
9. Rear Gate Garnish Assembly ...................................................................20

EB-2
EXTERIOR BODY PANEL
General Description
1. General Description
A: SPECIFICATION
(1) Front hood panel (4) Rear door panel (7) Side sill
(2) Front fender panel (5) Rear quarter panel
(3) Front door panel (6) Door panel
Section Part Specification
(A) Front hood panel to Front fender panel 3.5±1.0 mm (0.14±0.04 in)
(B) Front fender panel to Front door panel 4.7±1.0 mm (0.19±0.04 in)
(C) Front door panel to Rear door panel 5.0 mm (0.20 in)
(D) Rear door panel to Rear quarter panel 4.6 mm (0.18 in)
(E), (F) Door panel to Side sill 5.9 mm (0.23 in)
(A)
(A)
(C)
(D)(5) (4)(3)
(4)(2)
(3)
(B)
(6)
(7)
(E),(F) (1)
(2)(B)
(C)
(E)
(F)
(D)
EB-00001

EB-3
EXTERIOR BODY PANEL
General Description
B: COMPONENT
1. FRONT HOOD
(1) Front hood (3) SealTightening torque: N·m (kgf-m, ft-lb)
(2) HingeT1: 24.5 (2.5, 18.1)
EB-00038
(3)
T1
T1(2) (1)

EB-4
EXTERIOR BODY PANEL
General Description
2. FRONT FENDER PANEL
(1) Front fender panelTightening torque: N·m (kgf-m, ft-lb)
T: 7.4 (0.75, 5.5)
EB-00003
T
T
(1)

EB-5
EXTERIOR BODY PANEL
General Description
3. FRONT DOOR PANEL
(1) Gusset (9) Upper hingeTightening torque: N·m (kgf-m, ft-lb)
(2) Weather strip (10) Key cylinder (Driver’s side only)T1: 7.5 (0.76, 5.5)
(3) Stabilizer (Outer) (11) Front sashT2: 14 (1.4, 10.3)
(4) Stabilizer (Inner) (12) Rear sashT3: 25 (2.5, 18)
(5) Door panel (13) Guide railT4: 30 (3.1, 22)
(6) CheckerT5: 33 (3.4, 24)
(7) Sealing cover T6: 6 (0.6, 4.4)
(8) Lower hinge T7: 1.5 (0.15, 1.1)
EB-00183
T1
T6
T6
T3
T3
T4
T5
T4(4) (2)
(1)
(9)(5)
(6)
(13)
(12)(7)
(11) (8)(10)
T6
T6
T2
T2
T2
T2
T1
(3)
T7

EB-6
EXTERIOR BODY PANEL
General Description
4. REAR DOOR PANEL
(1) Weather strip (8) Rear sashTightening torque: N·m (kgf-m, ft-lb)
(2) Stabilizer (Outer) (9) Lower hingeT1: 7.5 (0.76, 5.5)
(3) Stabilizer (Inner) (10) Upper hingeT2: 25 (2.5, 18)
(4) Door panelT3: 30 (3.1, 18)
(5) CheckerT4: 33 (3.4, 24)
(6) Sealing coverT5: 14 (1.4, 10.3)
(7) Front sashT6: 1.5 (0.15, 1.1)
EB-00174
T1
T6
T1(1)
(3)
(7)
T2
T2
T6
T5
T3
T4T3(10)(4)
(5)
(6)
(9)
T5
(8)
(2)
T5T5

EB-7
EXTERIOR BODY PANEL
General Description
5. REAR GATE PANEL
(1) Damper stay (3) Rear gateTightening torque: N·m (kgf-m, ft-lb)
(2) Hinge (4) Rear gate garnishT1: 7.5 (0.76, 5.5)
T2: 14 (1.4, 10.1)
T3: 25 (2.5, 18.1)
EB-00037
T1
(2)
(3)
(4) (1)
T2
T3
T1
T1
T1

EB-8
EXTERIOR BODY PANEL
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
925610000 WRENCH Used for removing and installing door hinge.
TOOL NAME REMARKS
Support jack Used for supporting door panel.
ST-925610000

EB-9
EXTERIOR BODY PANEL
Front Hood Panel
2. Front Hood Panel
A: REMOVAL
1) Open the front hood to remove washer nozzles.
2) Release the clips to remove front hood insulator.
3) Remove the bolts to remove front hood from hinges.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the clearance between front hood panel
and front fender panel. Clearance must be equal at
both sides.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
C: ADJUSTMENT
1) Use the hinge mounting holes to align the front
hood longitudinally and laterally.
2) Adjust the height at front end of hood. SL-33, ADJUSTMENT, Front Hood Lock Assem-
bly.>3) Rotate the hood buffer to adjust lateral height.
EB-00008
EB-00009
EB-00009
EB-00010

EB-10
EXTERIOR BODY PANEL
Front Fender Panel
3. Front Fender Panel
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the front bumper face. REMOVAL, Front Bumper.>
3) Remove the mud guard. MOVAL, Mud Guard.>
4) Remove the side sill spoiler. MOVAL, Side Sill Spoiler.>
5) Remove the side protector. MOVAL, Side Garnish.>
6) Loosen the bolts and clip to remove front fender
panel.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When the front fender panel is installed, clear-
ance between front fender panel and front hood
panel must be equal.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.5 ft-lb)
EB-00011