roof SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 1 of 2870
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
Page 55 of 2870
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
Page 99 of 2870
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
Page 123 of 2870
AB-23
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
8) Extend the wiring of deployment tool to the limit,
and make sure that the vehicle is empty. Close all
the windows, sunroof and rear gate completely.
9) Move the battery at least 5 m (16 ft) from vehicle,
and secure the nearby area. Connect the deploy-
ment tool alligator clip to the battery negative (−)
terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
Do not let water get on the deployed airbag
module.
11) Remove the airbag module.
12) Wrap the deployed airbag module in airtight vi-
nyl bag, and discard it.2. PASSENGER’S AIRBAG MODULE
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
3) Remove the glove box.
4) Disconnect the airbag connectors (AB4) and
(AB27).
5) Short the terminal to alligator clip furnished as
deployment tool (A)
6) Connect the deployment tool (A) and deploy-
ment adapter E (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
7) Connect the deployment adapter E to the airbag
connector (AB27).
SB-00017
SB-00018
AB-00043
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter E:
(Tool number 98299SA030)
(1) Deployment adapter E:
(Tool number 98299SA030)
SB-00016
AB-00199
AB27
(1)
Page 124 of 2870
AB-24
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
8) Extend the wiring of deployment tool to the limit,
and make sure that the vehicle is empty. Close all
the windows, sunroof and rear gate completely.
9) Move the battery at least 5 m (16 ft) from vehicle,
and secure the nearby area. Connect the deploy-
ment tool alligator clip to the battery negative (−)
terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
Do not let water get on the deployed airbag
module.
11) Remove the airbag module.
12) Wrap the airbag module in an airtight vinyl bag,
and discard it.3. SIDE AIRBAG MODULE
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
3) Disconnect the side airbag module connector
(yellow) under the front seat cushion.
4) Set the backrest at most standing position, and
then set the seat position at center of slide rail.
5) Short the terminal to alligator clip furnished as
deployment tool (A)
6) Connect the deployment tool and deployment
adapter A (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
7) Connect the deployment adapter A (1) to the
side airbag module connector (yellow).
CAUTION:
Do not place any object on front seat.
Deploy the side airbag one by one to discard
it.
SB-00017
SB-00018
AB-00043
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter A:
(Tool number 98299FC030)
SB-00016
(1)
AB-00652
Page 125 of 2870
AB-25
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
8) Extend the wiring of deployment tool to the limit,
and make sure that the vehicle is empty. Close all
the windows, sunroof and rear gate completely.
9) Move the battery at least 5 m (16 ft) from vehicle,
and secure the nearby area. Connect the deploy-
ment tool alligator clip to the battery negative (−)
terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
Do not let water get on the deployed airbag
module.
11) Remove the side airbag module.
12) Wrap the deployed airbag module in airtight vi-
nyl bag, and discard it.
SB-00017
SB-00018
AB-00043
Page 131 of 2870
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
Page 233 of 2870
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
Page 246 of 2870
SB-12
SEAT BELT SYSTEM
Rear Seat Belt
5. Rear Seat Belt
A: REMOVAL
1. OUTER BELT SIDE
1) Remove the luggage floor mat.
2) Remove the rear seat.
3) Remove the rear quarter trim.
4) Remove the seat belt lower anchor bolt.
5) Remove the anchor cover. Remove the bolt and
shoulder anchor from pillar.
6) Remove the rear quarter trim.
7) Remove the bolts, and then detach the outer belt
side.8) Remove the two bolts and adjustable anchor as-
sembly.
2. OUTER BELT CENTER
1) Remove the anchor cover. Remove the bolt and
then detach the shoulder anchor from pillar.
2) Remove the strut cap.
3) Remove the rear rail trim.
4) Remove the rear pillar upper trim.
5) Remove the rear skirt trim.
6) Remove the rear quarter lower trim.
7) Remove the cover (B) while detaching snap lock
carefully. Put the outer belt center tongue (A) out to
the other side of the trim through the hole.
8) Remove the clips and hang down rear end of
roof trim.
SB-00008
SB-00009
SB-00010
SB-00011
SB-00009
SB-00012
Page 248 of 2870
SB-14
SEAT BELT SYSTEM
Disposal of Pretensioner
6. Disposal of Pretensioner
A: CAUTION
Do not discard undeployed pretensioners, because
they may cause serious personal injury when acci-
dentally deployed.
Deployment of the pretensioners should be done
on a flat place free from any possible danger. Avoid
deploying outdoors during heavy rainy or strong
windy weather.
Do not drop or damage the pretensioner.
Because deploying the pretensioners causes a
high-explosive noise, be sure to warn people in the
area, and do not allow anyone within a 5 m (16 ft)
radius of the disposal site.
Some smoke will be emitted after deployment of
the pretensioners. Therefore, it must be deployed
in a well-ventilated area with no smoke alarms
nearby.
Wear gloves, goggles, and earplugs during this
operation. Wash your hands afterwards.
After deployment, the pretensioner is especially
hot. Leave it unattended for 40 minutes or longer,
and then discard it.
Do not let water get on the deployed pretension-
er.
Wrap the deployed pretensioner in an airtight vi-
nyl bag, and then discard it.
If circumstances do not permit pretensioner de-
ployment, contact a SUBARU dealer.
B: OPERATION
1. DEPLOYING OF PRETENSIONER WHILE
INSTALLED IN VEHICLE
1) Fold backrest all the way forward, and then
move front seat all the way forward.
2) Turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the center pillar lower trim.
4) Disconnect the connector (A) of pretensioner.
5) Short the terminal to alligator clip furnished as
deployment tool (A).6) Connect the deployment tool and deployment
adapter D (B).
CAUTION:
The deployment tool terminals should be kept
shorted until just before deployment of the pre-
tensioner.
7) Connect the deployment adapter D connector and
pretensioner yellow connector.
8) Extend the deployment tool to the limit, and
make sure that the vehicle is empty. Close all win-
dows, sunroof, and rear gate completely.
9) Move the battery at least 5 m (16 ft) from the ve-
hicle, and secure the nearby area. Connect the de-
ployment tool alligator clip to the battery negative (−
) terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal. Then deploy the
pretensioner.
SB-00129
(A)
(A) Deployment tool: (Tool No. 98299PA030)
(B) Deployment adapter D: (Tool No. 98299SA010)
SB-00021
(A)
(B)
SB-00017
SB-00018