Subaru 2004 Forester Service Manual
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Subaru 2004 Forester Service Manual

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2004 FORESTER SERVICE MANUAL

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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)
AIRBAG SYSTEM
AIRBAG SYSTEM (DIAGNOSTIC)
SEAT BELT SYSTEM
LIGHTING SYSTEM
WIPER AND WASHER SYSTEM
ENTERTAINMENT
COMMUNICATION SYSTEM
GLASS/WINDOW/MIRROR
BODY STRUCTURE
INSTRUMENTATION/DRIVER INFO
SEAT
SECURITY AND LOCK
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
EXTERIOR/INTERIOR TRIM
EXTERIOR BODY PANEL
AC
AC
AB
AB
SB
LI
WW
ET
COM
GW
BS
IDI
SE
SL
SR
EI
EB
G8080GE7

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  • Page 1: Body Section

    2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM (HEATER, VENTILATOR AND A/C) HVAC SYSTEM (AUTO A/C) (DIAGNOSTIC) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTIC) This service manual has been prepared to provide SUBARU service personnel SEAT BELT SYSTEM with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 2 2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(H4SO) (DIAGNOSTIC) CRUISE CONTROL SYSTEM CC(H4DOTC) (DIAGNOSTIC) CRUISE CONTROL SYSTEM CC(H4DOTC 2.5) (DIAGNOSTIC) IMMOBILIZER (DIAGNOSTIC) G8080GE7...

  • Page 3: Table Of Contents

    EXTERIOR/INTERIOR TRIM Page General Description ..................2 Front Grille ....................18 Hood Grille ....................19 Front Under Cover ..................22 Front Bumper ....................23 Rear Bumper.....................30 Mud Guard ....................31 Cowl Panel ....................32 Side Sill Spoiler ..................33 Side Garnish .....................34 Front Door Trim ..................35 Rear Door Trim ..................36 Glove Box....................37 Roof Rail ....................38 Console Box....................39...

  • Page 4: General Description

    General Description EXTERIOR/INTERIOR TRIM 1. General Description A: COMPONENT 1. FRONT GRILLE EI-00230 Front grille Clip Hook Front grille emblem 2. UNDER COVER EI-00002 Under cover Clip Tightening torque: N·m (kgf-m, ft-lb) Service hole cover Bolt T: 18 (1.84, 13.3) EI-2...
  • Page 5 General Description EXTERIOR/INTERIOR TRIM 3. HOOD GRILLE (10) EI-00003 Hood grille Grille duct Tightening torque: N·m (kgf-m, ft-lb) Black clip Clip T: 4.4 (0.45, 3.25) Black clip Packing C Packing B Packing A Bolt (10) Duct bellows 4. HEAT SHIELD COVER EI-00089 Front heat shield cover Center heat shield cover...
  • Page 6 General Description EXTERIOR/INTERIOR TRIM 5. FRONT BUMPER (10) EI-00751 Bumper face Upper beam Tightening torque: N·m (kgf-m, ft-lb) E/A form Lower beam T1: 32 (3.3, 24) Fog light Lower beam reinforcement T2: 69 (7.0, 51) Side bracket Clip Main beam (10) Slider side front EI-4...
  • Page 7 General Description EXTERIOR/INTERIOR TRIM 6. REAR BUMPER EI-00005 Bumper face Rear bumper side bracket ASSY Tightening torque: N·m (kgf-m, ft-lb) Rear bumper upper beam Rear bumper upper beam side T1: 32 (3.3, 24) Rear arch cover T2: 7.4 (0.75, 5.46) Rear bumper front side bracket T3: 4.4 (0.45, 3.26) Center bracket...
  • Page 8 General Description EXTERIOR/INTERIOR TRIM 7. MUD GUARD EI-00238 Mud guard Screw Air flap Clip Clip (S-shape) EI-6...
  • Page 9 General Description EXTERIOR/INTERIOR TRIM 8. COWL PANEL EI-00724 Cowl panel Cowl side panel Seal EI-7...
  • Page 10 General Description EXTERIOR/INTERIOR TRIM 9. SIDE SILL SPOILER EI-00009 Side garnish (Front fender) Side garnish (Rear door) Side garnish (Side sill) Side garnish (Front door) Side garnish (Rear quarter) EI-8...
  • Page 11 General Description EXTERIOR/INTERIOR TRIM 10.ROOF RAIL EI-00010 Roof rail Tightening torque: N·m (kgf-m, ft-lb) T: 7.5 (0.76, 5.53) 11.DOOR TRIM EI-00233 Front door trim Rear door trim Gusset cover Clip Ash tray Bracket Trim panel Weather strip upper Power window switch cover EI-9...
  • Page 12 General Description EXTERIOR/INTERIOR TRIM 12.REAR GATE TRIM EI-00012 EI-10...
  • Page 13 General Description EXTERIOR/INTERIOR TRIM 13.CONSOLE BOX EI-00225 Rear cup holder Console front cover Accessory socket Console lid Console box Console cover Console pocket EI-11...

  • Page 14: Instrument Panel

    General Description EXTERIOR/INTERIOR TRIM 14.INSTRUMENT PANEL • LHD MODEL (12) (14) (15) (16) (13) (10) (11) EI-00793 Pad & frame Center panel (13) Grille cover Center compartment Air vent grille (14) Air vent grille (Defroster) Grille cover Cup holder (15) Switch panel Lower cover (10)
  • Page 15 General Description EXTERIOR/INTERIOR TRIM • RHD MODEL (12) (14) (15) (4) (16) (13) (10) (11) EI-00226 Pad & frame Center panel (13) Grille cover Center compartment Air vent grille (14) Air vent grille (Defroster) Grille cover Cup holder (15) Switch panel Lower cover (10) Glove box panel...
  • Page 16 General Description EXTERIOR/INTERIOR TRIM 15.INNER TRIM (14) (16) (15) (13) (10) (12) (11) EI-00015 Front pillar upper trim Rear skirt trim (15) Center pillar inner rib Center pillar upper trim Side sill rear cover (16) Bracket Rear pillar upper trim (10) Center pillar lower trim Rear rail trim...
  • Page 17 General Description EXTERIOR/INTERIOR TRIM 16.ROOF TRIM EI-00016 17.FLOOR MAT EI-00111 Vehicle front Floor mat EI-15...
  • Page 18 General Description EXTERIOR/INTERIOR TRIM 18.LUGGAGE FLOOR MAT EI-00220 Front floor mat Side floor mat RH Side floor mat LH Floor box Center floor mat EI-16...

  • Page 19: General Description

    General Description EXTERIOR/INTERIOR TRIM 19.INNER ACCESSORIES EI-00229 Hook Assist grip (Retractable) Tightening torque: N·m (kgf-m, ft-lb) Sun visor T: 2 (0.20, 1.46) B: PREPARATION TOOL TOOL NAME REMARKS Clip remover Used for removal of trim. Clip clamp pliers Used for removal of various clips and clamps. EI-17...

  • Page 20: Front Grille

    Front Grille EXTERIOR/INTERIOR TRIM 2. Front Grille B: INSTALLATION 1) Remove the three hooks remained on body dur- A: REMOVAL ing removal, then install them to front grille. 1) Open the front hood. 2) Remove the two upper clips of front grille side. Slide the front grille side to vehicle outside, then re- move the four lower hooks (A) to remove front grille side.

  • Page 21: Hood Grille

    Hood Grille EXTERIOR/INTERIOR TRIM 3. Hood Grille A: REMOVAL 1) Remove the five screws and clip (A) to remove hood duct. EI-00022 2) Remove the five nuts. EI-00023 3) Remove the three black clips to remove hood grille. EI-00024 EI-19...
  • Page 22 Hood Grille EXTERIOR/INTERIOR TRIM B: INSTALLATION EI-00025 Black clip Black clip Bolt 1) Replace the black clip (1), (2) with a new one. In- 4) Install the five nuts. stall the clip with arrow mark facing the front side of Tightening torque: grille (A).
  • Page 23 Hood Grille EXTERIOR/INTERIOR TRIM 6) Install the hood duct with clip (A) and five screws. EI-00022 C: INSPECTION Make sure that the clip is firmly engaged. Make sure that there is no abnormal gap at whole periphery of hood grille. Make sure that there is no damage on hood grille.

  • Page 24: Front Under Cover

    Front Under Cover EXTERIOR/INTERIOR TRIM 4. Front Under Cover A: REMOVAL 1) Lift-up the vehicle. 2) Loosen the bolts, remove the clips, and then re- move the under cover. EI-00030 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 18 N·m (1.84 kgf-m, 13.3 ft-lb) EI-22...

  • Page 25: Front Bumper

    Front Bumper EXTERIOR/INTERIOR TRIM 5. Front Bumper 5) Remove the front grille and front grille side. <Ref. to EI-18, REMOVAL, Front Grille.> A: REMOVAL 6) Remove the eight clips, and pull out the bumper 1) Disconnect the ground cable from battery. slightly.
  • Page 26 Front Bumper EXTERIOR/INTERIOR TRIM B: INSTALLATION Install in the reverse order of removal. Tightening torque: Refer to COMPONENT in General Descrip- tion. <Ref. to EI-4, FRONT BUMPER, COMPO- NENT, General Description.> EI-24...
  • Page 27 Front Bumper EXTERIOR/INTERIOR TRIM C: REPAIR 1. COATING METHOD FOR PP BUMPER Pro- cess Process name Job contents Set the bumper on paint worktable if required. Bumper mounting Use paint worktable conforming to inner shape of bumper when possible. EI-00038 (1) Bumper (2) Set bumper section Mask specified part (black base) with masking tape.
  • Page 28 Front Bumper EXTERIOR/INTERIOR TRIM 2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER NOTE: All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be re- stored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of the base material or coating, can be almost fully restored.
  • Page 29 Front Bumper EXTERIOR/INTERIOR TRIM 3) Deep damage such as a break or hole that requires filling Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really worth the expense. (The surface, however, will become almost flush with adjacent areas.) Recommended repair kit: PP Part Repair Kit (NRM) Pro- cess...
  • Page 30 Front Bumper EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam- aged area. Welding EI-00237 (1) Melt hatched area (2) Welding rod (3) Section NOTE: •...
  • Page 31 Front Bumper EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Solid color Metallic color Use a “block” coating method. Use a “block” coating method. • Recommended paint: • Recommended paint: Suncryl (SC) Suncryl (SC) No. 307 Flex Hardener No. 307 Flex Hardener SC Reducer (thinner) SC Reducer (thinner) Top coat (I)

  • Page 32: Rear Bumper

    Rear Bumper EXTERIOR/INTERIOR TRIM 6. Rear Bumper 7) Remove the rear skirt trim. 8) Remove the bolt to remove bracket from A: REMOVAL bumper. 1) Disconnect the ground cable from battery. 2) Remove the bolts and clips. EI-00047 9) Loosen the four nuts to remove rear bumper. EI-00046 10) Disengage the clips to remove bumper upper EI-00043...

  • Page 33: Mud Guard

    Mud Guard EXTERIOR/INTERIOR TRIM 7. Mud Guard A: REMOVAL 1) Jack-up the vehicle. 2) Remove the clip to remove air flap. 3) Remove the screws and clips to remove mud guard. EI-00049 B: INSTALLATION Install in the reverse order of removal. EI-31...

  • Page 34: Cowl Panel

    Cowl Panel EXTERIOR/INTERIOR TRIM 8. Cowl Panel A: REMOVAL 1) Open the front hood. 2) Remove the wiper arm. <Ref. to WW-12, RE- MOVAL, Front Wiper Arm.> 3) Remove the clips to remove cowl side panels. EI-00050 4) Loosen the clips to remove cowl panel. : (A) EI-0725 (A) Clip...

  • Page 35: Side Sill Spoiler

    Side Sill Spoiler EXTERIOR/INTERIOR TRIM 9. Side Sill Spoiler A: REMOVAL Remove the clips (one on front fender arch, six on bottom of side sill spoiler, one on top of side sill spoiler), then remove the side sill spoiler. EI-00053 B: INSTALLATION Install in the reverse order of removal.

  • Page 36: Side Garnish

    Side Garnish EXTERIOR/INTERIOR TRIM 10.Side Garnish B: INSTALLATION 1) Apply the PRIMER (SUMITOMO 3M K-500 or A: REMOVAL equivalent) widely to the slightly larger area where 1) Incise the edge of garnish using cutter, and then double-sided tape was adhered, and then adhere remove the garnish with pulling towards you by the double-sided tape (SUMITOMO 3M 5305 or hands.

  • Page 37: Front Door Trim

    Front Door Trim EXTERIOR/INTERIOR TRIM 11.Front Door Trim A: REMOVAL CAUTION: Do not apply excessive force to the clip. Other- wise the clip may be broken. 1) Disconnect the ground cable from battery. 2) Remove the gusset cover. 3) Pull up the inner remote cover toward you to re- move upper hook.

  • Page 38: Rear Door Trim

    Rear Door Trim EXTERIOR/INTERIOR TRIM 12.Rear Door Trim A: REMOVAL CAUTION: Do not apply excessive force to the clip. Other- wise the clip may be broken. 1) Disconnect the ground cable from battery. 2) Pull up the inner remote cover toward you to re- move upper hook.

  • Page 39: Glove Box

    Glove Box EXTERIOR/INTERIOR TRIM 13.Glove Box A: REMOVAL 1) Open the glove box. 2) Loosen the screws to remove glove box. EI-00057 (A) Hook (B) Clip B: INSTALLATION Install in the reverse order of removal. EI-37...

  • Page 40: Roof Rail

    Roof Rail EXTERIOR/INTERIOR TRIM 14.Roof Rail A: REMOVAL 1) Remove the roof trim. <Ref. to EI-47, REMOVAL, Roof Trim.> 2) Remove the five mounting nuts. 3) Detach the clip at front edge sideways carefully to remove the roof rail upwards. EI-00058 NOTE: Remove the clip at “C”...

  • Page 41: Console Box

    Console Box EXTERIOR/INTERIOR TRIM 15.Console Box 5) Loosen the screws. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console front cover. EI-00726 (A) Hook pawl 3) Remove the shift knob (MT model). 4) Loosen the screws to remove console cover. EI-00061 6) Remove the hook pawl of console side panel to remove console box.

  • Page 42: Instrument Panel Assembly

    Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 16.Instrument Panel Assembly 6) Loosen the screws. A: REMOVAL CAUTION: • All airbag system wiring harness and connec- tors are colored yellow. Do not use electrical test equipment on these circuits. • Be careful not to damage the airbag system harness when servicing the instrument panel.
  • Page 43 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 9) Loosen the screws and clips, and then remove NOTE: the side console panel. Remove the front pillar upper trim if necessary. <Ref. to EI-43, REMOVAL, Upper Inner Trim.> 19) Disconnect the combination meter harness con- nector.
  • Page 44 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 6) Loosen the four instrument panel installation bolts. B: INSTALLATION Install in the reverse order of removal. CAUTION: • Be careful not to snag the harness. • Make sure to connect the harness connector. NOTE: When setting the instrument panel into position, push the hook into grommet (A) on the body panel.

  • Page 45: Upper Inner Trim

    Upper Inner Trim EXTERIOR/INTERIOR TRIM 17.Upper Inner Trim A: REMOVAL 1) Remove the lower inner trim. <Ref. to EI-44, RE- MOVAL, Lower Inner Trim.> 2) Remove the front molding (A). 3) Remove the front pillar upper trim (B). 4) Detach the front seat belt shoulder anchor, then remove the center pillar upper trim (C).

  • Page 46: Lower Inner Trim

    Lower Inner Trim EXTERIOR/INTERIOR TRIM 18.Lower Inner Trim A: REMOVAL 1) Remove the side sill front cover (A). 2) Remove the rear seat cushion <Ref. to SE-13, REMOVAL, Rear Seat.>, then remove side sill rear cover (B). 3) Remove the center pillar lower trim (C). : (D) EI-00072 (D) Clip...

  • Page 47: Rear Quarter Trim

    Rear Quarter Trim EXTERIOR/INTERIOR TRIM 19.Rear Quarter Trim B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Remove the rear seat. <Ref. to SE-13, REMOV- Be sure to securely hook pawls of inner trim AL, Rear Seat.> panel to body flange.

  • Page 48: Sun Visor

    Sun Visor EXTERIOR/INTERIOR TRIM 20.Sun Visor A: REMOVAL Remove the mounting screws then detach sun vi- sor (A) and hook (B). EI-00074 B: INSTALLATION Install in the reverse order of removal. EI-46...

  • Page 49: Roof Trim

    Roof Trim EXTERIOR/INTERIOR TRIM 21.Roof Trim 8) Remove the clips, and then remove the roof trim. A: REMOVAL CAUTION: When removing the clip, use great care not to damage the roof trim. 1) Disconnect the ground cable from battery. 2) Remove the over head console. (Sunroof model) <Ref.

  • Page 50: Rear Gate Trim

    Rear Gate Trim EXTERIOR/INTERIOR TRIM 22.Rear Gate Trim A: REMOVAL CAUTION: Be careful not to damage the clips or their holes. Remove the rear gate inner handle (A) from rear gate and then detach trim panel. EI-00078 B: INSTALLATION Install in the reverse order of removal. EI-48...

  • Page 51: Floor Mat

    Floor Mat EXTERIOR/INTERIOR TRIM 23.Floor Mat A: REMOVAL 1) Remove the front seats. <Ref. to SE-6, REMOV- AL, Front Seat.> 2) Remove the rear seat cushion. <Ref. to SE-13, REMOVAL, Rear Seat.> 3) Remove the console box. <Ref. to EI-39, Con- sole Box.>...

  • Page 52: Luggage Floor Mat

    Luggage Floor Mat EXTERIOR/INTERIOR TRIM 24.Luggage Floor Mat A: REMOVAL 1) Remove the back mat of rear seat backrest. 2) Remove the clips, then detach the rear floor mats and boxes. EI-00080 B: INSTALLATION Install in the reverse order of removal. EI-50...

  • Page 53: Instrument Panel Center Compartment

    Instrument Panel Center Compartment EXTERIOR/INTERIOR TRIM 25.Instrument Panel Center Compartment A: REMOVAL 1) Disconnect the ground cable from battery. 2) Insert a flat tip screwdriver, and then pry up to re- move the clips. EI-00081 (A) Clip 3) Remove the instrument panel center compartment from instrument panel.

  • Page 54: Heat Shield Cover

    Heat Shield Cover EXTERIOR/INTERIOR TRIM 26.Heat Shield Cover A: REMOVAL 1. FRONT HEAT SHIELD COVER Loosen the four bolts to remove front heat shield cover. DI-00211 (A) Transmission mount 2. CENTER HEAT SHIELD COVER Loosen the four bolts to remove center heat shield cover.

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