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
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G8080GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4SO)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4DOTC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4DOTC 2.5)
IMMOBILIZER (DIAGNOSTIC) IM
EXTERIOR/INTERIOR TRIM
EI
Page
1. General Description ....................................................................................2
2. Front Grille ................................................................................................18
3. Hood Grille ................................................................................................19
4. Front Under Cover ....................................................................................22
5. Front Bumper ............................................................................................23
6. Rear Bumper.............................................................................................30
7. Mud Guard ................................................................................................31
8. Cowl Panel ................................................................................................32
9. Side Sill Spoiler .........................................................................................33
10. Side Garnish .............................................................................................34
11. Front Door Trim.........................................................................................35
12. Rear Door Trim .........................................................................................36
13. Glove Box..................................................................................................37
14. Roof Rail ...................................................................................................38
15. Console Box..............................................................................................39
16. Instrument Panel Assembly ......................................................................40
17. Upper Inner Trim .......................................................................................43
18. Lower Inner Trim .......................................................................................44
19. Rear Quarter Trim .....................................................................................45
20. Sun Visor...................................................................................................46
21. Roof Trim ..................................................................................................47
22. Rear Gate Trim .........................................................................................48
23. Floor Mat ...................................................................................................49
24. Luggage Floor Mat ....................................................................................50
25. Instrument Panel Center Compartment ....................................................51
26. Heat Shield Cover .....................................................................................52
EI-2
EXTERIOR/INTERIOR TRIM
General Description
1. General Description
A: COMPONENT
1. FRONT GRILLE
2. UNDER COVER
(1) Front grille (3) Clip (4) Hook
(2) Front grille emblem
(1) Under cover (3) Clip Tightening torque: N·m (kgf-m, ft-lb)
(2) Service hole cover (4) Bolt T: 18 (1.84, 13.3)
EI-00230
(1)
(2)
(3)
(4)
EI-00002
(1)
T
T
(2)
(3)
(4)
(3)
(3)
EI-3
EXTERIOR/INTERIOR TRIM
General Description
3. HOOD GRILLE
4. HEAT SHIELD COVER
(1) Hood grille (6) Grille duct Tightening torque: N·m (kgf-m, ft-lb)
(2) Black clip (7) Clip T: 4.4 (0.45, 3.25)
(3) Black clip (8) Packing C
(4) Packing B (9) Packing A
(5) Bolt (10) Duct bellows
(1) Front heat shield cover (2) Center heat shield cover (3) Rear heat shield cover
EI-00003
(1)
(2)
(6)
(7)
(3)
(3)
(4)
(9)
(8)
(5)
T
(10)
EI-00089
(1)
(2)
(3)
EI-4
EXTERIOR/INTERIOR TRIM
General Description
5. FRONT BUMPER
(1) Bumper face (6) Upper beam Tightening torque: N·m (kgf-m, ft-lb)
(2) E/A form (7) Lower beam T1: 32 (3.3, 24)
(3) Fog light (8) Lower beam reinforcement T2: 69 (7.0, 51)
(4) Side bracket (9) Clip
(5) Main beam (10) Slider side front
EI-00751
(1)
(2)
(3)
(4)
(6)
(5)
(7)
(8)
T1
T2
T1
T2
(9)
(9)
(9)
(9)
(10)
EI-5
EXTERIOR/INTERIOR TRIM
General Description
6. REAR BUMPER
(1) Bumper face (7) Rear bumper side bracket ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Rear bumper upper beam (8) Rear bumper upper beam side T1: 32 (3.3, 24)
(3) Rear arch cover T2: 7.4 (0.75, 5.46)
(4) Rear bumper front side bracket T3: 4.4 (0.45, 3.26)
(5) Center bracket T4: 93 (9.5, 68.7)
(6) Stay COMPL T5: 1.8 (0.18, 1.3)
EI-00005
T1
T1
T4
T5
T2
T3
T3
(2)
(8)
(3)
(7)
(5)
(1)
(4)
(6)
EI-6
EXTERIOR/INTERIOR TRIM
General Description
7. MUD GUARD
(1) Mud guard (3) Screw (5) Air flap
(2) Clip (4) Clip (S-shape)
EI-00238
(4)
(2)
(1)
(3)
(5)
(2)
(2)
EI-7
EXTERIOR/INTERIOR TRIM
General Description
8. COWL PANEL
(1) Cowl panel (2) Cowl side panel (3) Seal
EI-00724
(2)
(1)
(3)
(2)
EI-8
EXTERIOR/INTERIOR TRIM
General Description
9. SIDE SILL SPOILER
(1) Side garnish (Front fender) (3) Side garnish (Rear door) (5) Side garnish (Side sill)
(2) Side garnish (Front door) (4) Side garnish (Rear quarter)
EI-00009
(1)
(2)
(3)
(4)
(5)
EI-9
EXTERIOR/INTERIOR TRIM
General Description
10.ROOF RAIL
11.DOOR TRIM
(1) Roof rail Tightening torque: N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.53)
(A) Front door trim (B) Rear door trim
(1) Gusset cover (4) Clip (7) Ash tray
(2) Bracket (5) Trim panel
(3) Weather strip upper (6) Power window switch cover
EI-00010
T
(1)
EI-00233
(A)
(1)
(2)
(3)
(5)
(6)
(2)
(3)
(5)
(6)
(7)
(4)
(B)
(4)
EI-10
EXTERIOR/INTERIOR TRIM
General Description
12.REAR GATE TRIM
EI-00012
EI-11
EXTERIOR/INTERIOR TRIM
General Description
13.CONSOLE BOX
(1) Rear cup holder (4) Console front cover (7) Accessory socket
(2) Console lid (5) Console box
(3) Console cover (6) Console pocket
EI-00225
(1)
(2)
(3)
(4)
(5)
(7)
(6)
EI-12
EXTERIOR/INTERIOR TRIM
General Description
14.INSTRUMENT PANEL
• LHD MODEL
(1) Pad & frame (7) Center panel (13) Grille cover
(2) Center compartment (8) Air vent grille (14) Air vent grille (Defroster)
(3) Grille cover (9) Cup holder (15) Switch panel
(4) Lower cover (10) Glove box panel (16) Passenger’s airbag module
(5) Coin box (11) Glove box lid
(6) Meter visor (12) Steering beam
EI-00793
(9)
(14)
(16)
(4)
(3)
(2)
(13)
(12)
(11)
(15)
(1)
(8)
(10)
(5)
(6)
(7)
A
A
EI-13
EXTERIOR/INTERIOR TRIM
General Description
• RHD MODEL
(1) Pad & frame (7) Center panel (13) Grille cover
(2) Center compartment (8) Air vent grille (14) Air vent grille (Defroster)
(3) Grille cover (9) Cup holder (15) Switch panel
(4) Lower cover (10) Glove box panel (16) Passenger’s airbag module
(5) Coin box (11) Glove box lid
(6) Meter cover (12) Steering beam
EI-00226
(12)
(14)
(3)
(2)
(11)
(10)
(9)
(13)
(1)
(7)
(8)
(15)
(4)
(5)
(6)
A
A
(16)
EI-14
EXTERIOR/INTERIOR TRIM
General Description
15.INNER TRIM
(1) Front pillar upper trim (8) Rear skirt trim (15) Center pillar inner rib
(2) Center pillar upper trim (9) Side sill rear cover (16) Bracket
(3) Rear pillar upper trim (10) Center pillar lower trim
(4) Rear rail trim (11) Side sill front cover Tightening torque: N·m (kgf-m, ft-lb)
(5) Insulator (12) Front garnish T: 2 (0.20, 1.46)
(6) Rear quarter lower trim (13) Rear garnish
(7) Strut cap (14) Front pillar inner rib
EI-00015
(1)
(2)
(3)
(6)
(5)
(8)
(9)
(10)
(11)
(13)
(14)
(15)
(16)
(7)
(4)
T
T
(12)
EI-15
EXTERIOR/INTERIOR TRIM
General Description
16.ROOF TRIM
17.FLOOR MAT
(A) Vehicle front
(1) Floor mat
EI-00016
EI-00111
(A)
(1)
EI-16
EXTERIOR/INTERIOR TRIM
General Description
18.LUGGAGE FLOOR MAT
(1) Front floor mat (3) Side floor mat RH (5) Side floor mat LH
(2) Floor box (4) Center floor mat
EI-00220
(3)
(2)
(4)
(5)
(1)
EI-17
EXTERIOR/INTERIOR TRIM
General Description
19.INNER ACCESSORIES
B: PREPARATION TOOL
(1) Hook (3) Assist grip (Retractable) Tightening torque: N·m (kgf-m, ft-lb)
(2) Sun visor T: 2 (0.20, 1.46)
TOOL NAME REMARKS
Clip remover Used for removal of trim.
Clip clamp pliers Used for removal of various clips and clamps.
EI-00229
(2)
(1)
T
T
T
T
T
(3)
EI-18
EXTERIOR/INTERIOR TRIM
Front Grille
2. Front Grille
A: REMOVAL
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.
3) Remove the four upper clips (A) of front grille,
then pull the front grille up and remove the three
hooks (B) to remove front grille.
B: INSTALLATION
1) Remove the three hooks remained on body dur-
ing removal, then install them to front grille.
NOTE:
Make sure that the clip direction is correct.
2) Install the front grille to body.
3) Install the front grille side.
(A) Hook
(A) Clip
(B) Hook
EI-00019
: (A)
EI-00020
: (A) : (B)
EI-00021
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