SUBARU FORESTER 2004 Service Repair Manual

EB-11
EXTERIOR BODY PANEL
Front Door Panel
4. Front Door Panel
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the front door trim. MOVAL, Front Door Trim.>
3) Remove the outer mirror assembly. GW-12, REMOVAL, Outer Mirror Assembly.>
4) Remove the front sealing cover. REMOVAL, Front Sealing Cover.>
5) Remove the front door glass. REMOVAL, Front Door Glass.>
6) Remove the front door regulator and motor. to GW-21, REMOVAL, Front Regulator and Motor
Assembly.>
7) Remove the front door latch assembly. SL-24, REMOVAL, Front Door Latch Assembly.>
8) Remove the front outer handle. REMOVAL, Front Outer Handle.>
9) Remove the front pillar lower trim to disconnect
the connector from body harness.
10) Put a wooden block on jack and place jack under
door. Support the door with a jack to protect it from
damage.
NOTE:
When supporting the door with a jack, be careful
not to deform the door hinges while working.11) Remove the checker bolts.
12) Remove the door-side bolts for upper and low-
er hinges to remove the front door panel.
13) Using the ST, remove the body-side bolts for
upper and lower hinges, and remove door hinges.
ST 925610000 WRENCH
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to the sliding area of door hinges.
3) Refer to COMPONENT in General Description for
tightening torque. EL, COMPONENT, General Description.>
EB-00012
EB-00013
EB-00014
EB-00015
EB-00016
ST

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-13
EXTERIOR BODY PANEL
Front Sealing Cover
5. Front Sealing Cover
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the front door trim. REMOVAL, Front Door Trim.>
3) Remove the front speaker. MOVAL, Front Speaker.>
4) Remove the door trim bracket.
5) Remove the sealing cover.
NOTE:
 Carefully remove the butyl tape. Excessive force
will easily break the cover.
 If the cover gets broken, replace it with a new
one.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing the sealing cover, use butyl tape.
3) Press the butyl tape-applied area firmly to pre-
vent any floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
 Apply a uniform bead of butyl tape.
 Attach the sealing cover, keeping it from becom-
ing wrinkled.
 Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If the sealing cover is damaged, replace it with a
new one.
EB-00034
EB-00018

EB-14
EXTERIOR BODY PANEL
Rear Door Panel
6. Rear Door Panel
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the rear door trim. MOVAL, Rear Door Trim.>
3) Remove the rear sealing cover. REMOVAL, Rear Sealing Cover.>
4) Remove the rear door glass. REMOVAL, Rear Door Glass.>
5) Remove the rear door regulator and motor as-
sembly. tor and Motor Assembly.>
6) Remove the rear door latch assembly. SL-28, REMOVAL, Rear Door Latch Assembly.>
7) Remove the rear outer handle. REMOVAL, Rear Outer Handle.>
8) Remove the center pillar lower trim. 44, REMOVAL, Lower Inner Trim.>
9) Remove the seat belt bracket and blind plug.
Disconnect the connector of door harness and re-
move the door hinge nut.
10) Put a wooden block on the jack and place the
jack under the door. Support the door with the jack
to protect it.
NOTE:
When supporting the door with a jack, be careful
not to deform the door hinges while working.11) Remove the checker bolts.
12) Remove the door-side bolts for upper and low-
er hinges to remove the rear door panel.
13) Using the ST, remove the body-side bolts for
upper and lower hinges, and remove door hinges.
ST 925610000 WRENCH
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to the sliding area of door hinges.
3) Refer to COMPONENT in General Description for
tightening torque. PANEL, COMPONENT, General Description.>
C: ADJUSTMENT
1) Using the ST, loosen the body-side bolts of up-
per and lower hinges to align the position of rear
door panel longitudinally and vertically.
ST 925610000 WRENCH
EB-00019
EB-00013
EB-00014
EB-00015
EB-00016
ST

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-16
EXTERIOR BODY PANEL
Rear Sealing Cover
7. Rear Sealing Cover
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the rear door trim. MOVAL, Rear Door Trim.>
3) Remove the door trim bracket.
4) Remove the sealing cover.
NOTE:
 Carefully remove the butyl tape. Excessive force
will easily break the cover.
 If the cover gets broken, replace it with a new
one.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing the sealing cover, use butyl tape.
3) Press the butyl tape-applied area firmly to pre-
vent any floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
 Apply an uniform bead of butyl tape.
 Attach the sealing cover, keeping it from becom-
ing wrinkled.
 Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If the sealing cover is damaged, replace it with a new
one.
EB-00034
EB-00018

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-18
EXTERIOR BODY PANEL
Rear Gate Panel
2. REAR GATE DAMPER STAY
1) Open the rear gate. Use a support to support the
rear gate.
NOTE:
After the rear gate damper stay is removed, the rear
gate cannot stay open. Supporting the rear gate with
a jack, remove the bolts.
CAUTION:
 Do not damage the piston rods and oil seals.
 Never disassemble the cylinders: They con-
tain gas.
2) Loosen the bolts to remove the rear gate damper
stay from rear gate.
B: INSTALLATION
1. REAR GATE PANEL
1) Install in the reverse order of removal.
2) Install the rear gate panel with uniform clearance
to the body.
3) Refer to COMPONENT of General Description for
tightening torque. EL, COMPONENT, General Description.>
NOTE:
After supporting the rear gate with a jack, start
working.
2. REAR GATE DAMPER STAY
1) Install the mounting bolt (A) to the rear gate pan-
el and body.
Tightening torque:
14 N·m (1.43 kgf-m, 10.3 ft-lb)
2) Firmly install the rear gate damper stay (B) to
mounting bolt (A).
3) Tighten the bolts at upper side of rear gate damp-
er stay.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
EB-00021
EB-00024
(A)(B)
EB-00075

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)