Subaru Forester Service Manual
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Subaru Forester Service Manual

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See also: Service Manual , Owner's 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: Quick Reference Index

    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: Body Structure

    BODY STRUCTURE Page General Description ..................2 Datum Points....................3 Datum Dimensions..................11...

  • Page 4: General Description

    General Description BODY STRUCTURE 1. General Description A: PREPARATION TOOL TOOL NAME REMARKS Tram tracking gauge Used for measuring dimen- sion. Tape measure Used for measuring dimen- sion. BS-2...

  • Page 5: Datum Points

    Datum Points BODY STRUCTURE 2. Datum Points A: LOCATION NOTE: • Datum points are specified for body repair. • Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment accuracy. • Both right and left reference points are symmetrical. (38) (39) (35)
  • Page 6 Datum Points BODY STRUCTURE Radiator panel gauge hole 6 mm (14) Fender attaching hole 10 mm (31) Harness attaching hole 7 mm (0.24 in) dia. (Vehicle center) (0.39 in) dia. (Symmetrical) (0.28 in) dia. (Symmetrical) Radiator attaching hole 12 mm (15) Fender attaching hole 10 mm (32)
  • Page 7 Datum Points BODY STRUCTURE (27) (29) (18) (28) (44) (31) (18) (44) (45) (19) (46) (47) (48) (24) (42) (41) (45) (43) (46) (43) (47) (48) BS-00002 (18) Front weather strip attaching hole (31) Harness attaching hole 7 mm (45) Combination light attaching hole 5.2 mm (0.20 in) dia.
  • Page 8 Datum Points BODY STRUCTURE (36) (62) (63) (61) (66) (52) (53) (54) (65) (12) (55) (56) (57) (58) (59) (60) (64) (51) (51) (64) (52) (53) (54) (65) (12) (55) (56) (57) (58) (59) (60) (61) (66) (62) (63) (36) BS-00003 (12) Front strut attaching hole 9.5 mm...
  • Page 9 Datum Points BODY STRUCTURE BS-00005 BS-00004 BS-00007 BS-00006 (10) (12) (11) BS-00008 BS-00009 (14) (18) (16) (19) (17) (13) (15) BS-00010 BS-00011 BS-7...
  • Page 10 Datum Points BODY STRUCTURE (23) (21) (24) (20) (22) BS-00015 BS-00014 (27) (25) (26) (28) BS-00016 BS-00017 (29) (34) (31) (30) BS-00019 BS-00018 (37) (32) (35) (36) (33) BS-00020 BS-00021 BS-8...
  • Page 11 Datum Points BODY STRUCTURE (38) (42) (39) (40) (41) BS-00022 BS-00023 (43) (44) BS-00024 BS-00025 (46) (45) (54) (65) (52) (47) (48) (53) (51) BS-00027 BS-00026 (56) (58) (55) (57) (59) (60) BS-00028 BS-00029 BS-9...
  • Page 12 Datum Points BODY STRUCTURE (63) (66) (62) (61) BS-00030 BS-00031 (64) BS-00032 BS-10...

  • Page 13: Datum Dimensions

    Datum Dimensions BODY STRUCTURE 3. Datum Dimensions A: MEASUREMENT Refer to LOCATION for details on measurement points. <Ref. to BS-3, LOCATION, Datum Points.> NOTE: • Using a tram tracking gauge, measure all dimen- sions. • When using a tape measure, carefully measure dimensions without letting the tape measure sag or twist.
  • Page 14 Datum Dimensions BODY STRUCTURE 1. CENTER STRUCTURE (12) (36) (64) (62) (52) (53) (54) (61) (55) (57)(58) (59) 11(0.43) 9(0.35) 20(0.79) 14(0.55) 317(12.48) 485(19.09) 585(23.03) 77(3.03) 474(18.66) 329(12.95) 135(5.31) 620(24.41) 356(14.02) 1070(42.13) 1270(50.00) 694(27.32) 230(9.06) (36) (12) (53) (61) (64) (52) (54) (55)

  • Page 15: Suspension Crossmember

    Datum Dimensions BODY STRUCTURE 2. SUSPENSION CROSSMEMBER (62) (54) (65) (66) (63) 75(2.95) 139(5.47) 2547(100.28) 150(5.91) (62) (54) (63) (66) (65) (65) (66) (63) (54) (62) BS-00036 *1: Standard line *2: Side sill Unit: mm (in) BS-13...

  • Page 16: Front Structure

    Datum Dimensions BODY STRUCTURE 3. FRONT STRUCTURE (13) (10) (13) (12) (11) (10) (12) (14) (15) BS-00037 Unit: mm (in) Point to point Dimension Point to point Dimension (1) to (11) 822 (32.36) (7) LH to (15) LH 1,067 (42.01) (2) RH to (11) 842 (33.15) (8) RH to (8) LH...
  • Page 17 Datum Dimensions BODY STRUCTURE (38) (32) (39) (35) (40) (29) (33) (36) (30) (34) (36) (25) (26) (37) (23) (31) (21) (22) (20) (16) (17) BS-00038 Unit: mm (in) Point to point Dimension Point to point Dimension (16) RH to (20) RH 980 (38.58) (30) LH to (33) LH 796 (31.34)
  • Page 18 Datum Dimensions BODY STRUCTURE 4. REAR STRUCTURE (27) (18) (29) (19) (28) (18) (44) (24) (31) (19) (44) (24) (41) (42) (46) (45) (47) (46) (48) (45) (47) (48) BS-00039 Unit: mm (in) Point to point Dimension Point to point Dimension (18) RH to (18) LH 1,449 (57.05)

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