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

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

WW-2
WIPER AND WASHER SYSTEM
General Description
1. General Description
A: SPECIFICATION
B: COMPONENT
1. FRONT WIPER
Front wiper motor Input 12 V — 72 W or less
Rear wiper motor Input 12 V — 42 W or less
Front washer motor Pump type Centrifugal
Input 12 V — 36 W or less
Rear washer motor Pump type Centrifugal
Input 12 V — 36 W or less
(1) Wiper rubber (4) Wiper rink Tightening torque: N·m (kgf-m, ft-lb)
(2) Wiper blade ASSY (5) Wiper motor T1: 6.0 (0.61, 4.4)
(3) Wiper arm T2: 20 (2.0, 14.5)
WW-00223
T1
T1
T1
T1
T2
T2
(4)
(5)
(3)
(2)
(1)
(3)
(2)
(1)

WW-3
WIPER AND WASHER SYSTEM
General Description
2. REAR WIPER
(1) Wiper rubber (7) Spacer B Tightening torque: N·m (kgf-m, ft-lb)
(2) Wiper blade ASSY (8) Nut T1: 6.0 (0.61, 4.4)
(3) Wiper arm (9) Cap T2: 7.5 (0.76, 5.5)
(4) Wiper motor (10) Wiper arm cover T3: 8.0 (0.82, 5.9)
(5) Spacer A
(6) Cushion
WW-00190
T1
(5)
(1)
T2
T3
(2)
(6)
(7)
(9)
(3)
(8)
(4)
(10)

WW-4
WIPER AND WASHER SYSTEM
General Description
3. WASHER TANK
(1) Washer nozzle (7) Grommet (13) Valve
(2) Washer hose (8) Headlight washer motor
(3) Washer tank (9) Motor bracket Tightening torque: N·m (kgf-m, ft-lb)
(4) Washer tank cap (10) Headlight washer case T: 6.0 (0.61, 4.4)
(5) Front washer motor (11) Headlight washer upper nozzle
(6) Rear washer motor (12) Headlight washer lower nozzle
WW-00097
(1)
(1)
(1)
(2)
(2)
(10)
(11)
(12)
(13)
(2)
(2)
(8)
(7)
(6)
(5)
(9)
T
(3)
(4)

WW-5
WIPER AND WASHER SYSTEM
General Description
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.
• Wiring harnesses and connectors of all airbag
system are yellow color. Do not use a tester on
these circuits.
• Care must be taken when installing the piping
hose so that no bending, jamming, etc. are caused.
• If even a little oil or grease such as silicon oil gets
in the tank and washer passages, an oil film easily
forms on the glass, causing the wiper to chatter and
judder. Therefore, be careful not to let this happen.

WW-6
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
Wiper and washers do not operate. (1) Wiper fuse (F/B No. 14, 15)
(2) Combination switch
(3) Wiper motor
(4) Wiring harness
Wipers do not operate in LO or HI. (1) Combination switch
(2) Wiper motor
(3) Wiring harness
Wipers do not operate in INT. (1) Combination switch
(2) Wiper motor
(3) Wiring harness
Washer motor does not operate. (1) Washer switch
(2) Washer motor
(3) Wiring harness
Wipers do not operate when washer switch is ON. (1) Washer motor
(2) Wiring harness
Washer fluid spray does not operate. (1) Washer motor
(2) Washer hose and nozzle

WW-7
WIPER AND WASHER SYSTEM
Combination Switch (Wiper)
3. Combination Switch (Wiper)
A: REMOVAL
1) Loosen the screw to remove the steering column
cover.
2) Disconnect the connectors from combination
switches.
3) Loosen the screw to remove combination switch.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Inspect the continuity between each connector
terminal.
LHD and RHD for Europe model:
WW-00004
WW-00045
Switch position Terminal No. Standard
FRONT
OFF 7 and 16 Less than 1 Ω
INT 7 and 16 Less than 1 Ω
LO 7 and 17 Less than 1 Ω
HI 8 and 17 Less than 1 Ω
Washer ON 2 and 11 Less than 1 Ω
REAR
Washer ON
2 and 10
10 and 12
2 and 12
Less than 1 Ω
OFF — More than 1 MΩ
INT 2 and 13 Less than 1 Ω
ON 2 and 10 Less than 1 Ω
Washer ON
2 and 10
10 and 12
2 and 12
Less than 1 Ω
WW-00046
876543219
17 16 15 14 13 12 11 1018

WW-8
WIPER AND WASHER SYSTEM
Combination Switch (Wiper)
RHD except for Europe model:
2) If continuity is not as specified, replace the switch.
• Intermittent operation inspection
(1) Turn the wiper switch to INT.
(2) Adjust the intermittent control switch to MAX.
(3) Apply battery voltage to switch terminals 16 and 2.
(4) Measure the voltage between combination switch terminal.
Terminals:
No. 7 — No. 2:
If operation is not as specified, replace the switch.
Switch position Terminal No. Standard
FRONT
OFF 3 and 12 Less than 1Ω
INT 3 and 12 Less than 1Ω
LO 3 and 11 Less than 1Ω
HI 2 and 11 Less than 1Ω
Washer ON 8 and 17 Less than 1Ω
REAR
Washer ON
8 and 18
18 and 16
8 and 16
Less than 1Ω
OFF — More than 1MΩ
INT 8 and 15 Less than 1Ω
ON 8 and 18 Less than 1Ω
Washer ON
8 and 18
18 and 16
8 and 16
Less than 1Ω
WW-00053
(A) (B)
(C)
(H)
(I)
(J)
(D)
(F)
(G)
(F)
(G)
(F)
(G)
(E)
(A) Switch position (E) Non variable type (I) 16±6 sec.
(B) Voltage (F) 12 V (J) 3±1 sec.
(C) MIN. (G) 0 V
(D) MAX. (H) Approx. 2 sec.

WW-9
WIPER AND WASHER SYSTEM
Wiper Blade
4. Wiper Blade
A: REMOVAL
While pushing the locking clip (A) up, pull out the
blade from arm to arrow direction.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Confirm that the clip is locked securely.
C: DISASSEMBLY
Pull on side (A) of the wiper rubber stopper and re-
move the rubber from the blade assembly.
D: ASSEMBLY
1. METAL TYPE
1) Insert the wiper rubber onto the blade so that the
stopper is in the position shown.
2) Make sure the wiper rubber is securely fastened
to the pull stopper (A).
WW-00008
WW-00009
WW-00049
WW-00037

WW-10
WIPER AND WASHER SYSTEM
Wiper Blade
2. RESIN TYPE
1) Insert the wiper rubber through the claw (B).
2) Insert the wiper rubber top until it protrudes about
20 mm (0.79 in) from the stopper (D).
3) Insert the wiper rubber into the claw (A).
E: INSPECTION
1) When the wiper does not perform well, inspect
the following:
• Make sure the movable part of the blade assem-
bly moves smoothly.
• Make sure the wiper rubber is not deformed or
damaged.
2) Replace with a new part if damage is found.
WW-00193
ABCD
(A) 20 mm (0.79 in)
WW-00198
A
B
WW-00199
D
(A)
A
WW-00147

WW-11
WIPER AND WASHER SYSTEM
Washer Tank and Motor
5. Washer Tank and Motor
A: REMOVAL
1) Open the hood.
2) Disconnect the ground cable from battery.
3) Remove the two bolts, hose and connector, and
then remove the tank.
4) For the model with headlight washer, proceed to
step 5) and 6).
5) Lift the washer tank, and then disconnect the con-
nector from headlight washer motor. Disconnect
washer hoses.
6) Disconnect the washer hose from the motor, and
then detach the washer tank.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.0 N·m (0.61 kgf-m, 4.4 ft-lb)
C: DISASSEMBLY
1) Remove bolt, and then pull out washer motor
from tank. (Model with headlight washer)
2) Pull out the washer motor from tank.
D: ASSEMBLY
1) Assemble in the reverse order of disassembly.
2) Confirm that water does not leak from installa-
tion area of motor.
E: INSPECTION
Apply battery voltage to the connector terminal of
the washer motor and make sure the motor oper-
ates.
WW-00011
WW-00098
WW-00099
WW-00100
WW-00012
WW-00013

WW-12
WIPER AND WASHER SYSTEM
Front Wiper Arm
6. Front Wiper Arm
A: REMOVAL
1) Open the hood.
2) Remove the cap.
3) Loosen the nut to remove arm.
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.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
<Ref. to WW-2, FRONT WIPER, COMPO-
NENT, General Description.>
C: ADJUSTMENT
Operate the wiper once. Align the wiper blade to
ceramic print point mark (A) of front window panel.
WW-00047
WW-00048
(A)
WW-00048
(A)

WW-13
WIPER AND WASHER SYSTEM
Front Wiper Motor and Link
7. Front Wiper Motor and Link
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the cowl panel. <Ref. to EI-32, REMOV-
AL, Cowl Panel.>
3) Disconnect the connector of motor.
4) Loosen the bolts and nuts to remove wiper link.
5) Loosen the bolts and nuts to remove motor.
B: INSTALLATION
1) Install the wiper link to the vehicle, and then con-
nect the motor connector.
2) Connect the battery ground cable to battery.
3) To confirm that the motor is at auto stop position,
connect the harness to motor and turn the wiper
switch ON/OFF once.
4) Disconnect the ground cable from battery.
5) Tighten the nut where rod (A) and link plate (B) is
aligned in a straight line.
6) Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
<Ref. to WW-2, FRONT WIPER, COMPO-
NENT, General Description.>
C: INSPECTION
1) When the battery is connected to wiper motor
connectors and confirm that motor operates at low
speed.
2) When the battery is connected to terminal of
connectors and confirm that motor operates at high
speed.
3) Connect the battery to terminals of connector,
and remove the terminal connection with motor ro-
tated at low speed, and stop the wiper motor
through operation.
WW-00050
WW-00051
WW-00052
(A)
(B)
WW-00224
32
54
1
32
54
1
WW-00225
WW-00226
32
54
1

WW-14
WIPER AND WASHER SYSTEM
Front Wiper Motor and Link
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
32
54
1

WW-15
WIPER AND WASHER SYSTEM
Front Washer Nozzle
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.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Hoses have rib as eyemark for twist-proof.
2) Adjust the position of the washer liquid sprayer.
<Ref. to WW-15, ADJUSTMENT, Front Washer
Nozzle.>
C: INSPECTION
• Make sure the nozzle and hose are not clogged.
• Check hoses for twist or fold.
D: ADJUSTMENT
NOTE:
It is not necessary to adjust the washer injection
position because of spreading nozzle type.
WW-00023

WW-16
WIPER AND WASHER SYSTEM
Rear Wiper Arm
9. Rear Wiper Arm
A: REMOVAL
1) Remove the wiper arm cover (A).
2) Loosen the nut to remove wiper arm.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Operate the rear wiper once.
3) Align the blade to the center of rear defogger
heat wire (A).
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
<Ref. to WW-3, REAR WIPER, COMPONENT,
General Description.>
C: ADJUSTMENT
1) Operate the rear wiper once.
2) Align the blade to the center of rear defogger
heat wire (A).
WW-00191
WW-00192
WW-00200
WW-00200

WW-17
WIPER AND WASHER SYSTEM
Rear Wiper Motor
10.Rear Wiper Motor
A: REMOVAL
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.
4) Remove the rear gate lower trim. <Ref. to EI-48,
REMOVAL, Rear Gate Trim.>
5) Unclip the clip of harness and disconnect the
connector of wiper motor.
6) Loosen the bolts to remove the wiper motor as-
sembly (A).
B: INSTALLATION
1) Install in the reverse order of removal.
2) Install the rear wiper cushion with the arrow
mark facing up, as shown in the figure.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
<Ref. to WW-3, REAR WIPER, COMPONENT,
General Description.>
C: INSPECTION
1) Connect the battery to wiper motor connector
and confirm that the wiper motor operates.
2) Connect the battery to terminal of connector and
remove the terminal connections with motor rotat-
ed, and stop the wiper motor through operation.
3) Connect the battery and confirm that the motor
stops at automatic stop position after the motor op-
erates at low speed again.
WW-00027
WW-00028
WW-00029
WW-00030
2 1
4 3
WW-00031
2 1
4 3
WW-00032
2 1
4 3

WW-18
WIPER AND WASHER SYSTEM
Rear Washer
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.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the position of the washer liquid sprayer.
<Ref. to WW-18, ADJUSTMENT, Rear Washer.>
C: INSPECTION
• Make sure the nozzle and hose are not clogged.
• Check hoses for twist or fold.
D: ADJUSTMENT
1) Turn the wiper switch to OFF position.
2) When the vehicle stops, adjust the washer injec-
tion position as shown in the figure.
Injection position:
A: 35 mm (1.38 in)
B: 72
°
(1) Nozzle
WW-00201
WW-00054
A
(1)
B