torque SUBARU FORESTER 2004 Service Manual PDF

EI-38
EXTERIOR/INTERIOR TRIM
Roof Rail
14.Roof Rail
A: REMOVAL
1) Remove the roof trim.
2) Remove the five mounting nuts.
3) Detach the clip at front edge sideways carefully to remove the roof rail upwards.
NOTE:
Remove the clip at “C” area upwards while applying sideway force to deflect hook at “a” area.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be careful not to scratch the body panels with
roof rail stud bolts when removing and install-
ing them.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.53 ft-lb)
A
C
A
ABA
a
CBA
EI-00058

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-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

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-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