Subaru Forester Service Manual
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Subaru Forester Service Manual

2004
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Table of Contents

See also: Owner's Manual , Instruction Manual
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

    WIPER AND WASHER SYSTEM Page General Description ..................2 Wiper and Washer System .................6 Combination Switch (Wiper)................7 Wiper Blade....................9 Washer Tank and Motor................11 Front Wiper Arm..................12 Front Wiper Motor and Link...............13 Front Washer Nozzle ................15 Rear Wiper Arm ..................16 Rear Wiper Motor..................17 Rear Washer .....................18 Wiper Control Relay ..................19 Headlight Washer..................20...

  • Page 4: General Description

    General Description WIPER AND WASHER SYSTEM 1. General Description A: SPECIFICATION Front wiper motor Input 12 V — 72 W or less Rear wiper motor Input 12 V — 42 W or less Pump type Centrifugal Front washer motor Input 12 V —...
  • Page 5 General Description WIPER AND WASHER SYSTEM 2. REAR WIPER (10) WW-00190 Wiper rubber Spacer B Tightening torque: N·m (kgf-m, ft-lb) Wiper blade ASSY T1: 6.0 (0.61, 4.4) Wiper arm T2: 7.5 (0.76, 5.5) Wiper motor (10) Wiper arm cover T3: 8.0 (0.82, 5.9) Spacer A Cushion WW-3...
  • Page 6 General Description WIPER AND WASHER SYSTEM 3. WASHER TANK (10) (11) (12) (13) WW-00097 Washer nozzle Grommet (13) Valve Washer hose Headlight washer motor Washer tank Motor bracket Tightening torque: N·m (kgf-m, ft-lb) Washer tank cap (10) Headlight washer case T: 6.0 (0.61, 4.4) Front washer motor (11)

  • Page 7: General Description

    General Description WIPER AND WASHER SYSTEM C: CAUTION • Reconnect the connectors and hoses securely. After reconnecting, confirm that each function oper- ates normally. • Be careful that wiring harnesses of airbag sys- tem pass near electrical parts and switches. •...

  • Page 8: Wiper And Washer System

    Wiper and Washer System WIPER AND WASHER SYSTEM 2. Wiper and Washer System A: WIRING DIAGRAM 1. WIPER AND WASHER (FRONT) <Ref. to WI-264, WIRING DIAGRAM, Wiper and Washer System (Front).> 2. WIPER AND WASHER (REAR) <Ref. to WI-265, WIRING DIAGRAM, Wiper and Washer System (Rear).> B: INSPECTION Symptom Repair order...

  • Page 9: Combination Switch (Wiper)

    Combination Switch (Wiper) WIPER AND WASHER SYSTEM 3. Combination Switch (Wiper) C: INSPECTION 1) Inspect the continuity between each connector A: REMOVAL terminal. 1) Loosen the screw to remove the steering column cover. WW-00004 2) Disconnect the connectors from combination switches.
  • Page 10 Combination Switch (Wiper) WIPER AND WASHER SYSTEM RHD except for Europe model: Switch position Terminal No. Standard 3 and 12 Less than 1Ω 3 and 12 Less than 1Ω FRONT 3 and 11 Less than 1Ω 2 and 11 Less than 1Ω Washer ON 8 and 17 Less than 1Ω...

  • Page 11: Wiper Blade

    Wiper Blade WIPER AND WASHER SYSTEM 4. Wiper Blade 2) Make sure the wiper rubber is securely fastened to the pull stopper (A). A: REMOVAL While pushing the locking clip (A) up, pull out the blade from arm to arrow direction. WW-00037 WW-00008 B: INSTALLATION...
  • Page 12 Wiper Blade WIPER AND WASHER SYSTEM 2. RESIN TYPE WW-00193 1) Insert the wiper rubber through the claw (B). 3) Insert the wiper rubber into the claw (A). WW-00198 WW-00147 2) Insert the wiper rubber top until it protrudes about E: INSPECTION 20 mm (0.79 in) from the stopper (D).

  • Page 13: Washer Tank And Motor

    Washer Tank and Motor WIPER AND WASHER SYSTEM 5. Washer Tank and Motor C: DISASSEMBLY 1) Remove bolt, and then pull out washer motor A: REMOVAL from tank. (Model with headlight washer) 1) Open the hood. 2) Disconnect the ground cable from battery. 3) Remove the two bolts, hose and connector, and then remove the tank.

  • Page 14: Front Wiper Arm

    Front Wiper Arm WIPER AND WASHER SYSTEM 6. Front Wiper Arm A: REMOVAL 1) Open the hood. 2) Remove the cap. 3) Loosen the nut to remove arm. WW-00047 B: INSTALLATION 1) Install in the reverse order of removal. 2) Operate the wiper once. 3) Align the wiper blade to ceramic print point mark (A) of front window panel.

  • Page 15: Front Wiper Motor And Link

    Front Wiper Motor and Link WIPER AND WASHER SYSTEM 7. Front Wiper Motor and Link 6) Install in the reverse order of removal. Tightening torque: A: REMOVAL Refer to COMPONENT in General Descrip- 1) Disconnect the ground cable from battery. tion.
  • Page 16 Front Wiper Motor and Link WIPER AND WASHER SYSTEM 4) Connect the battery and confirm that the motor stops at automatic stop position after the motor op- erates at low speed again. WW-00227 WW-14...

  • Page 17: Front Washer Nozzle

    Front Washer Nozzle WIPER AND WASHER SYSTEM 8. Front Washer Nozzle A: REMOVAL 1) Remove the washer hose from the washer noz- zle. 2) Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle.

  • Page 18: Rear Wiper Arm

    Rear Wiper Arm WIPER AND WASHER SYSTEM 9. Rear Wiper Arm C: ADJUSTMENT 1) Operate the rear wiper once. A: REMOVAL 2) Align the blade to the center of rear defogger 1) Remove the wiper arm cover (A). heat wire (A). WW-00191 WW-00200 2) Loosen the nut to remove wiper arm.

  • Page 19: Rear Wiper Motor

    Rear Wiper Motor WIPER AND WASHER SYSTEM 10.Rear Wiper Motor C: INSPECTION 1) Connect the battery to wiper motor connector A: REMOVAL and confirm that the wiper motor operates. 1) Disconnect the ground cable from battery. 2) Remove the rear wiper arm. 3) Remove the cap (A), nut (B), and spacer (C) from rear wiper shaft.

  • Page 20: Rear Washer

    Rear Washer WIPER AND WASHER SYSTEM 11.Rear Washer A: REMOVAL 1) Remove the rear gate upper trim. <Ref. to EI-48, REMOVAL, Rear Gate Trim.> 2) Remove the washer hose from the washer noz- zle. 3) Push the anchor portion of washer nozzle with a thin screwdriver or other tool, and remove the washer nozzle.

  • Page 21: Wiper Control Relay

    Wiper Control Relay WIPER AND WASHER SYSTEM 12.Wiper Control Relay 3) Measure the voltage when the wiper relay is op- erated. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the right quarter lower trim. <Ref. to EI- 45, REMOVAL, Rear Quarter Trim.>...

  • Page 22: Headlight Washer

    Headlight Washer WIPER AND WASHER SYSTEM 13.Headlight Washer B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Disconnect the ground cable from the battery. 2) Remove the front grille. <Ref. to EI-18, REMOV- AL, Front Grille.> 3) Remove the headlight. <Ref. to LI-13, REMOV- AL, Headlight Assembly.>...

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