Subaru Forester User manual

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

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

BS-2
BODY STRUCTURE
General Description
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-3
BODY STRUCTURE
Datum Points
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.
BS-00001
(6)
(7)
(3)
(4)
(5)
(5)
(4)
(2)
(1) (3)
(2)
(8)
(9)
(10)
(12)
(11)
(31)
(33)
(36)
(13)
(29)
(34)
(13)
(32)
(23)
(30)
(35)
(38) (39)
(40)
(25)
(26)
(21)
(22)
(20)
(14)
(16)
(17)
(15)
(10)
(12)
(9)
(6)
(7)
(8)
(37)

BS-4
BODY STRUCTURE
Datum Points
(1) Radiator panel gauge hole 6 mm
(0.24 in) dia. (Vehicle center)
(14) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)
(31) Harness attaching hole 7 mm
(0.28 in) dia. (Symmetrical)
(2) Radiator attaching hole 12 mm
(0.47 in) dia.
(15) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)
(32) Trim attaching hole 8.5 mm (0.33
in) dia. (Symmetrical)
(3) Headlight attaching hole 7 mm
(0.28 in) dia. (Symmetrical)
(16) Front door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)
(33) Trim attaching hole 7 mm (0.28 in)
dia. (Symmetrical)
(4) Frame plate gauge hole 8 mm
(0.31 in) dia. (Symmetrical)
(17) Front door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)
(34) Harness attaching hole 7×7 mm
(0.28×0.28 in) (Symmetrical)
(5) Bumper beam attaching hole 11
mm (0.43 in) dia. (Symmetrical)
(20) Front door switch attaching hole
4.1 mm (0.16 in) dia. (Symmetri-
cal)
(35) Tonneau cover bracket attaching
hole 5.5 mm (0.22 in) dia. (Sym-
metrical)
(6) Fender attaching hole 7 mm (0.28
in) dia. (Symmetrical) (21) Rear door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)
(36) Rear strut attaching hole 10 mm
(0.39 in) (Symmetrical)
(7) Fender attaching hole 9 mm (0.35
in) dia. (Symmetrical) (22) Rear door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)
(37) Floor mat attaching hole 8 mm
(0.31 in) dia.
(8) Power steering tank attaching hole
RH ATF cooler pipe attaching hole
LH 9 mm (0.35 in) dia. (23) Front weather strip attaching hole
5.2 mm (0.20 in) dia. (Symmetri-
cal)
(38) Trim attaching hole 9×9 mm
(0.35×0.35 in) (Symmetrical)
(9) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)
(39) Trim attaching hole 8 mm (0.31 in)
dia. (Symmetrical)
(25) Rear weather strip attaching hole
5.2 mm (0.20 in) dia. (Symmetri-
cal)
(10) Fender attaching hole 7 mm (0.28
in) dia. (Symmetrical)
(40) Trim attaching hole 8 mm (0.31 in)
dia. (Symmetrical)
(11) Modular bracket gauge hole 8 mm
(0.31 in) dia. (Vehicle center)
(26) Rear door switch attaching hole
4.1 mm (0.16 in) dia. (Symmetri-
cal)
(12) Front strut attaching hole 9.5 mm
(0.37 in) dia. (Symmetrical) (29) Trim attaching hole 8.5 mm (0.33
in) dia. (Symmetrical)
(13) Front glass attaching hole LH
6.5×10.5 mm (0.26×0.41 in) RH
6.5×7 mm (0.26×0.28 in) (30) Pad attaching hole 5 mm (0.20 in)
dia. (Symmetrical)

BS-5
BODY STRUCTURE
Datum Points
(18) Front weather strip attaching hole
5.2 mm (0.20 in) dia. (Symmetri-
cal)
(31) Harness attaching hole 7 mm
(0.28 in) dia. (Symmetrical)
(45) Combination light attaching hole
9.5 mm (0.37 in) dia. (Symmetri-
cal)
(41) Harness attaching hole 7.5 mm
(0.30 in) dia.
(19) Trim attaching hole 7 mm (0.28 in)
dia. (Symmetrical)
(46) Combination light attaching hole 7
mm (0.28 in) dia. (Symmetrical)
(42) Bumper beam attaching hole 12
mm (0.47 in) dia.
(24) Trim attaching hole 7 mm (0.28 in)
dia. (Symmetrical)
(47) Combination light attaching hole
8×15 mm (0.31×0.59 in) (Symmet-
rical)
(43) Striker gauge hole 5 mm (0.20 in)
dia. (Symmetrical)
(27) Front pillar gauge hole 12 mm
(0.47 in) dia. (Symmetrical) (44) Harness attaching hole 7×7 mm
(0.28×0.28 in) dia. (Symmetrical)
(48) Bumper bracket attaching hole 7
mm (0.28 in) dia. (Symmetrical)
(28) Insulator attaching hole 8 mm
(0.31 in) dia. (Symmetrical)
(29) Trim attaching hole 8.5 mm (0.33
in) dia. (Symmetrical)
BS-00002
(48)
(44)
(47)
(43)
(42)
(48)
(47)
(46)
(45)
(29)
(28)
(18)
(27)
(31)
(43)
(41)
(44)
(24)
(19)
(18)
(45)
(46)

BS-6
BODY STRUCTURE
Datum Points
(12) Front strut attaching hole 9.5 mm
(0.37 in) dia. (Symmetrical)
(56) Transverse link attaching hole 16
mm (0.63 in) dia. (Symmetrical)
(62) Rear cross member gauge hole
16 mm (0.63 in) dia. (Symmetri-
cal)
(36) Rear strut attaching hole 10 mm
(0.39 in) dia. (Symmetrical)
(57) Sub-frame attaching hole 16 mm
(0.63 in) dia. (Symmetrical) (63) Rear cross member attaching hole
12 mm (0.47 in) dia. (Symmetri-
cal)
(51) Radiator lower frame gauge hole
12 mm (0.47 in) dia. (Symmetri-
cal)
(58) Transmission cross member
attaching hole 14 mm (0.55 in)
dia. (Symmetrical) (64) Rear bumper beam attaching hole
RH 15 mm (0.57 in) dia. LH 19×15
mm (0.75×0.59 in)
(52) Side frame gauge hole 20 mm
(0.79 in) dia. (Symmetrical)
(59) Rear side frame gauge hole 15
mm (0.59 in) dia. (Symmetrical)
(53) Sub-frame attaching hole 16 mm
(0.63 in) dia. (Symmetrical)
(60) Rear side frame gauge hole 18
mm (0.71 in) dia. (Symmetrical)
(65) Front cross member attaching
hole 12.4 mm (0.49 in) dia. (Sym-
metrical)
(54) Front cross member attaching
hole 12.4 mm (0.49 in) dia. (Sym-
metrical)
(61) Rear differential attaching hole 16
mm (0.63 in) dia. (Symmetrical) (66) Rear cross member attaching hole
16 mm (0.63 in) dia. (Symmetri-
cal)
(55) Transverse link attaching hole 17
mm (0.69 in) dia. (Symmetrical)
BS-00003
(52) (53) (54)(65) (12) (55) (61)
(61)
(64)
(64)
(51)
(51)
(36)
(36)
(66)
(66)
(56) (57) (58) (59) (60)
(52) (53) (54) (65) (12) (55) (56) (57) (58) (59) (60)
(62)
(62)
(63)
(63)

BS-7
BODY STRUCTURE
Datum Points
(1)
(2)
(2)
BS-00004 BS-00005
(4)
(5)
(3)
BS-00006
(6)
(7)
(8)
BS-00007
(8)
BS-00008
(9)
(10)
(12)
BS-00009
(11)
BS-00010
(13)
BS-00011
(14)
(16) (18)
(17)
(15)
(19)

BS-8
BODY STRUCTURE
Datum Points
BS-00014
(23)
(20)
(21)
(22)
BS-00015
(24)
BS-00016
(25)
(26)
BS-00017
(27)
(28)
BS-00018
(29)
(30)
BS-00019
(34)
(31)
BS-00020
(32)
(33)
(35)
(36)
BS-00021
(37)

BS-9
BODY STRUCTURE
Datum Points
(38)
(39)
(40)
BS-00022
(41)
(42)
BS-00023
(43)
BS-00024
(44)
BS-00025
(46)
(45)
(47) (48)
BS-00026
(51)
(52)
(53)
(54) (65)
BS-00027
(56)
(58)
(57)
(55)
BS-00028 (59) (60) BS-00029

BS-10
BODY STRUCTURE
Datum Points
(61) BS-00030
(66) (62)
(63)
BS-00031
(64)
BS-00032

BS-11
BODY STRUCTURE
Datum Dimensions
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.
• Measure the linear dimensions between cores of
holes.
• Suffixes “RH” and “LH” indicate right-hand and
left-hand.
• Measure at the center of the circle around the
outside of the body panel.
(1) Tram tracking gauge
(1) Datum point
(2) Body panel
(3) Outside
BS-00033
(1)
BS-00034
(1)
(3)
(2)

BS-12
BODY STRUCTURE
Datum Dimensions
1. CENTER STRUCTURE
*1: Standard line
*2: Side sill
*3: Upper surface
Unit: mm (in)
BS-00035
(54)(53)
(52)
(55) (59)
(57)(58)
(12)
(52)
(52)
(55)
(55)
(56)
(56)
(57)
(57)
(58)
(58)
(59)
(53)
(53)
(54)
(54)
(12)
(12)
2
9(0.35) 11(0.43)
77(3.03)
620(24.41)
910(35.83) 906(35.67) 856(33.70)
(62) (64)
(61)
(36)
11
3
694(27.32)
230(9.06)
1070(42.13) 1270(50.00)
585(23.03)
500(19.69)
(61)
(61)
(64)
(64)
(63)
(63)
(62)
(62)
(36)
(36)
1136(44.72) 1221(48.07)
3
474(18.66)
621(24.45)
(51)
(51)
860(33.86)
1065(41.93)
(60)
(59) (60)
630(24.80)
(52)
(55)
(57)
(53)
(53)
(54)
924(36.38)
917(36.10)
1209(47.60)
1005(39.57)
(61) (64)
(62)
(59) (60)
1207(47.52)
1124(44.25)
206(8.11)
77(3.03)
20(0.79) 14(0.55)
135(5.31)
669(26.34)
205(8.07)
356(14.02)
485(19.09)317(12.48)
329(12.95)
1110(43.70)
920(36.22)
920(36.22)
838(32.99)
529(20.83)
780(30.71)
776(30.55)
878(34.57)
1438(56.61)
1332(52.44)
1205(47.44)
882(34.72)
954(37.56)

BS-13
BODY STRUCTURE
Datum Dimensions
2. SUSPENSION CROSSMEMBER
*1: Standard line
*2: Side sill
Unit: mm (in)
BS-00036
(54)
(54)
(65)
(65)
(54)
(66) (63)
2
75(2.95)
150(5.91)
2547(100.28)
860(33.86) 840(33.07)
(62)
(65)
11
(66)
(66)
(63)
(63)
(62)
(62)
920(36.22)
206(8.11) 139(5.47) 205(8.07)

BS-14
BODY STRUCTURE
Datum Dimensions
3. FRONT STRUCTURE
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 921 (36.26)
(2) LH to (11) 875 (34.45) (9) RH to (9) LH 1,396 (54.96)
(3) RH to (3) LH 716 (28.19) (9) RH to (10) RH 398 (15.67)
(4) RH to (4) LH 978 (38.50) (9) LH to (10) LH 398 (15.67)
(5) RH to (5) LH 1,049 (41.30) (9) RH to (11) 767 (30.20)
(6) RH to (6) LH 1,341 (52.80) (9) LH to (11) 767 (30.20)
(6) RH to (9) RH 349 (13.74) (10) RH to (11) 722 (28.43)
(6) LH to (9) LH 349 (13.74) (10) LH to (11) 722 (28.43)
(6) RH to (11) 944 (37.17) (10) RH to (13) RH 907 (35.71)
(6) LH to (11) 944 (37.17) (10) LH to (13) LH 907 (35.71)
(7) RH to (14) RH 1,155 (45.47) (11) to (12) RH 565 (22.24)
(7) LH to (14) LH 1,155 (45.47) (11) to (12) LH 565 (22.24)
(7) RH to (15) RH 1,067 (42.01) (12) RH to (12) LH 1,065 (41.93)
(6)
(6)
(5)
(5)
(4)
(4)
(1)
(3)
(2)
(9)
(10)
(13)
BS-00037
(2)
(13)
(11) (10)
(12)
(14)
(15)
(3)
(9)
(8)
(7)
(8)
(12)

BS-15
BODY STRUCTURE
Datum Dimensions
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)
(16) LH to (20) LH 980 (38.58) (31) RH to (34) RH 759 (29.88)
(17) RH to (20) RH 982 (38.66) (31) LH to (34) LH 759 (29.88)
(17) LH to (20) LH 982 (38.66) (35) RH to (38) RH 665 (26.18)
(21) RH to (25) RH 853 (33.58) (35) LH to (38) LH 665 (26.18)
(21) LH to (25) LH 853 (33.58) (35) RH to (39) RH 711 (27.99)
(22) RH to (26) RH 895 (35.24) (35) LH to (39) LH 711 (27.99)
(22) LH to (26) LH 895 (35.24) (35) RH to (40) RH 784 (30.87)
(23) LH to (23) RH 1,429 (56.26) (35) LH to (40) LH 784 (30.87)
(29) RH to (32) RH 674 (26.54) (36) LH to (36) RH 1,221 (48.07)
(29) LH to (32) LH 674 (26.54) (36) RH to (37) RH 1,067 (42.01)
(30) RH to (33) RH 796 (31.34) (36) LH to (37) LH 1,067 (42.01)
BS-00038
(30)
(29)
(17)
(16) (22)
(26)
(25) (36)
(36)
(37)
(38)
(39)
(40)
(35)
(20)
(21)
(23)
(33)
(34)
(31)
(32)

BS-16
BODY STRUCTURE
Datum Dimensions
4. REAR STRUCTURE
Unit: mm (in)
Point to point Dimension Point to point Dimension
(18) RH to (18) LH 1,449 (57.05) (41) RH to (43) RH 794 (31.26)
(19) RH to (19) LH 1,459 (57.44) (41) LH to (43) LH 805 (31.69)
(27) RH to (29) RH 1,007 (39.65) (42) RH to (42) LH 1,110 (43.70)
(27) LH to (29) LH 1,007 (39.65) (44) RH to (44) LH 878 (34.57)
(28) RH to (31) RH 813 (32.01) (45) RH to (45) LH 1,474 (58.03)
(28) LH to (31) LH 813 (32.01) (46) RH to (46) LH 1,252 (49.29)
(24) RH to (24) LH 1,438 (56.61) (47) RH to (47) LH 1,552 (61.10)
(41) RH to (41) LH 950 (37.40) (48) RH to (48) LH 1,210 (47.64)
BS-00039
(48)
(48)
(47)
(47)
(46)
(46)
(45)
(45)
(18)
(29)
(44)
(41)
(42)
(44)
(31)
(24)
(24)
(28)
(18)
(19)
(27)
(19)