Removal SUBARU FORESTER 2004 Service Manual Online

GW-12
GLASS/WINDOW/MIRROR
Outer Mirror Assembly
6. Outer Mirror Assembly
A: REMOVAL
1) Remove the door trim. AL, Front Door Trim.>
2) Remove the mirror gusset cover.
3) Disconnect the mirror connector.
4) Remove the grommet, and then loosen the
screws to remove mirror assembly.
B: INSTALLATION
Install in the reverse order of removal.
(1) Hook
: (1)
GW-00061
GW-00010

GW-14
GLASS/WINDOW/MIRROR
Outer Mirror
7. Outer Mirror
A: REPLACEMENT
1) Remove the door mirror assembly. 12, REMOVAL, Outer Mirror Assembly.>
2) Warm the area around the mirror holder (1) with
a hair drier until the edges of the mirror holder be-
come soft (about 2 or 3 minutes with a 1,000 W dri-
er.)
3) Use a flat tip screwdriver without sharp edges to
lift the mirror out of the mirror holder. (Also discon-
nect the heated mirror connector from the back of
mirror.)
4) When installing the mirror, warm the area around
the mirror holder with a hair drier until the edges of
the mirror holder become soft again (about 2 or 3
minutes with a 1,000 W drier.)
5) Remove the backing of the new double-stick
tape, and push the mirror in to install it.
NOTE:
Unless the mirror holder is warmed sufficiently, the
mirror holder edges may be damaged or the mirror
cracked.
GW-00062
(1)

GW-15
GLASS/WINDOW/MIRROR
Remote Control Mirror Switch
8. Remote Control Mirror
Switch
A: REMOVAL
Refer to Power Window Control Switch, because the
remote control mirror switch is integrated with power
window control switch. Power Window Control Switch.>
B: INSTALLATION
Refer to Power Window Control Switch, because the
remote control mirror switch is integrated with power
window control switch. TION, Power Window Control Switch.>

GW-17
GLASS/WINDOW/MIRROR
Front Door Glass
9. Front Door Glass
A: REMOVAL
1) Remove the front door trim. MOVAL, Front Door Trim.>
2) Remove the front speaker. MOVAL, Front Speaker.>
3) Remove the sealing cover. MOVAL, Front Sealing Cover.>
4) Remove the outer mirror assembly. 12, REMOVAL, Outer Mirror Assembly.>
5) Remove the front end of door weather strip and
gusset.
6) Remove the stabilizers.7) Remove the rear end of door weather strip and
weather strip outer.
8) Operate the power window switch to move the
glass to position shown in the figure, and then re-
move the three nuts from service holes.
9) Take out the door glass.
NOTE:
 Do not turn the regulator in closing direction after
removal of the glass. Otherwise gear may be disen-
gaged.
 Avoid impact and damage to the glass.
GW-00013
GW-00014
GW-00015
GW-00017

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-21
GLASS/WINDOW/MIRROR
Front Regulator and Motor Assembly
10.Front Regulator and Motor
Assembly
A: REMOVAL
1) Remove the door glass. MOVAL, Front Door Glass.>
2) Loosen the nuts to remove rear sash.
3) Disconnect the motor connector.
4) Loosen the four bolts and two nuts to remove
regulator assembly.
5) Loosen the screw to remove motor assembly.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the front door glass. JUSTMENT, Front Door Glass.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. COMPONENT, General Description.>
C: INSPECTION
1) Make sure that the power window motor rotates
properly when battery voltage is applied to the ter-
minals of motor connector.
2) Change polarity of battery connections to termi-
nals to ensure that the motor rotates in reverse di-
rection.
GW-00027
GW-00028
GW-00029

GW-22
GLASS/WINDOW/MIRROR
Rear Door Glass
11.Rear Door Glass
A: REMOVAL
1) Remove the rear door trim. MOVAL, Rear Door Trim.>
2) Remove the front speaker. MOVAL, Front Speaker.>
3) Remove the sealing cover. MOVAL, Rear Sealing Cover.>
4) Remove the stabilizer.
5) Remove the door weather strip.6) Loosen the two screws to remove the weather
strip outer.
7) Operate the power window switch to remove glass
as shown in the figure, and then remove two nuts.
8) Take out the door glass.
CAUTION:
Avoid impact and damage to the glass.
GW-00030
GW-00057
GW-00032
GW-00031

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-24
GLASS/WINDOW/MIRROR
Rear Regulator and Motor Assembly
12.Rear Regulator and Motor As-
sembly
A: REMOVAL
1) Remove the door glass. MOVAL, Rear Door Glass.>
2) Remove the front sash.
3) Disconnect the motor connector.
4) Loosen the four bolts and two nuts to remove
regulator assembly.
5) Loosen the screws to remove motor assembly.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the rear door glass. JUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. COMPONENT, General Description.>
C: INSPECTION
1) Make sure that the power window motor rotates
properly when battery voltage is applied to the ter-
minals of motor connector.
2) Change polarity of battery connections to the ter-
minals to ensure that the motor rotates in reverse
direction.
GW-00035
GW-00036

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