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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, reassembling, inspection and adjustment of components and diagnostics for guidance 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.
QUICK REFERENCE INDEX
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)
AIRBAG SYSTEM
AC
AC
AB
AB AIRBAG SYSTEM (DIAGNOSTIC)
SEAT BELT SYSTEM SB
LI LIGHTING SYSTEM
ET ENTERTAINMENT
COMMUNICATION SYSTEM COM
GW GLASS/WINDOW/MIRROR
BODY STRUCTURE BS
IDI INSTRUMENTATION/DRIVER INFO
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB
All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
G8080GE7
2004 FORESTER SERVICE MANUAL
BODY SECTION
QUICK REFERENCE INDEX
CRUISE CONTROL SYSTEM
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
IMMOBILIZER (DIAGNOSTIC)
CC
CC(H4SO)
CC(H4DOTC)
CC(H4DOTC 2.5)
IM
G8080GE7
WIPER AND WASHER SYSTEM
WW
Page
Wiper and Washer System .........................................................................6
Combination Switch (Wiper)........................................................................7
Washer Tank and Motor............................................................................11
Front Wiper Motor and Link.......................................................................13
General Description
WIPER AND WASHER SYSTEM
1. General Description
A: SPECIFICATION
Front wiper motor
Rear wiper motor
Front washer motor
Rear washer motor
Input
Input
Pump type
Input
Pump type
Input
B: COMPONENT
1. FRONT WIPER
12 V — 72 W or less
12 V — 42 W or less
Centrifugal
12 V — 36 W or less
Centrifugal
12 V — 36 W or less
(1)
(2)
T1
T1
(3)
(1)
T2
(4)
(2)
T1
(5)
T1
T2
(3)
(1) Wiper rubber
(2) Wiper blade ASSY
(3) Wiper arm
(4) Wiper rink
(5) Wiper motor
WW-2
WW-00223
Tightening torque: N·m (kgf-m, ft-lb)
T1: 6.0 (0.61, 4.4)
T2: 20 (2.0, 14.5)
2. REAR WIPER
General Description
WIPER AND WASHER SYSTEM
T3
(10)
(9)
(8)
T2
(7)
(6)
(5)
T1
(4)
(1)
(3)
(1) Wiper rubber
(2) Wiper blade ASSY
(3) Wiper arm
(4) Wiper motor
(5) Spacer A
(6) Cushion
(7) Spacer B
(8) Nut
(9) Cap
(10) Wiper arm cover
(2)
WW-00190
Tightening torque: N·m (kgf-m, ft-lb)
T1: 6.0 (0.61, 4.4)
T2: 7.5 (0.76, 5.5)
T3: 8.0 (0.82, 5.9)
WW-3
WIPER AND WASHER SYSTEM
3. WASHER TANK
(1)
(10)
(11)
(2)
General Description
(4)
(9)
(8)
(12)
T
(1)
(2)
(13)
(3)
(5)
(6)
(7)
(1)
(2)
(2)
(1)
(2)
(3)
(4)
(5)
(6)
Washer nozzle
Washer hose
Washer tank
Washer tank cap
Front washer motor
Rear washer motor
(7)
(8)
Grommet
Headlight washer motor
(9) Motor bracket
(10) Headlight washer case
(11) Headlight washer upper nozzle
(12) Headlight washer lower nozzle
WW-00097
(13) Valve
Tightening torque: N·m (kgf-m, ft-lb)
T: 6.0 (0.61, 4.4)
WW-4
General Description
C: CAUTION
• Reconnect the connectors and hoses securely.
After reconnecting, confirm that each function operates normally.
• Be careful that wiring harnesses of airbag system 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.
WIPER AND WASHER SYSTEM
WW-5
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
Wiper and washers do not operate.
Wipers do not operate in LO or HI.
Wipers do not operate in INT.
Washer motor does not operate.
Wipers do not operate when washer switch is ON.
Washer fluid spray does not operate.
Repair order
(1) Wiper fuse (F/B No. 14, 15)
(2) Combination switch
(3) Wiper motor
(4) Wiring harness
(1) Combination switch
(2) Wiper motor
(3) Wiring harness
(1) Combination switch
(2) Wiper motor
(3) Wiring harness
(1) Washer switch
(2) Washer motor
(3) Wiring harness
(1) Washer motor
(2) Wiring harness
(1) Washer motor
(2) Washer hose and nozzle
WW-6
Combination Switch (Wiper)
3. Combination Switch (Wiper)
A: REMOVAL
1) Loosen the screw to remove the steering column cover.
WIPER AND WASHER SYSTEM
C: INSPECTION
1) Inspect the continuity between each connector terminal.
WW-00004
2) Disconnect the connectors from combination switches.
3) Loosen the screw to remove combination switch.
B: INSTALLATION
Install in the reverse order of removal.
WW-00045
9
18
8 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10
WW-00046
LHD and RHD for Europe model:
FRONT
REAR
Switch position Terminal No.
OFF
INT
LO
7 and 16
7 and 16
7 and 17
HI
Washer ON
Washer ON
8 and 17
2 and 11
2 and 10
10 and 12
2 and 12
OFF
INT
ON
Washer ON
—
2 and 13
2 and 10
2 and 10
10 and 12
2 and 12
Standard
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
More than 1 M
Ω
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
WW-7
Combination Switch (Wiper)
WIPER AND WASHER SYSTEM
RHD except for Europe model:
FRONT
REAR
Switch position Terminal No.
OFF 3 and 12
INT
LO
HI
Washer ON
3 and 12
3 and 11
2 and 11
Washer ON
OFF
INT
ON
8 and 17
8 and 18
18 and 16
8 and 16
—
8 and 15
Washer ON
8 and 18
8 and 18
18 and 16
8 and 16
Standard
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
More than 1M
Ω
Less than 1
Ω
Less than 1
Ω
Less than 1
Ω
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:
(A) (B)
(C)
(D)
(E)
(F)
(G)
(F)
(G)
(F)
(G)
(H)
(I)
(J)
(A) Switch position
(B) Voltage
(C) MIN.
(D) MAX.
(E) Non variable type
(F) 12 V
(G) 0 V
(H) Approx. 2 sec.
If operation is not as specified, replace the switch.
(I) 16
±6 sec.
(J) 3
±1 sec.
WW-00053
WW-8
4. Wiper Blade
Wiper Blade
WIPER AND WASHER SYSTEM
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
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 remove the rubber from the blade assembly.
WW-00009
D: ASSEMBLY
1. METAL TYPE
1) Insert the wiper rubber onto the blade so that the stopper is in the position shown.
WW-00049
WW-9
WIPER AND WASHER SYSTEM
2. RESIN TYPE
Wiper Blade
A B C D
1) Insert the wiper rubber through the claw (B).
WW-00193
3) Insert the wiper rubber into the claw (A).
A
A
B
WW-00198
2) Insert the wiper rubber top until it protrudes about
20 mm (0.79 in) from the stopper (D).
D
(A)
WW-00147
E: INSPECTION
1) When the wiper does not perform well, inspect the following:
• Make sure the movable part of the blade assembly moves smoothly.
• Make sure the wiper rubber is not deformed or damaged.
2) Replace with a new part if damage is found.
WW-00199
(A) 20 mm (0.79 in)
WW-10
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.
WIPER AND WASHER SYSTEM
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.
WW-00100
WW-00011
4) For the model with headlight washer, proceed to step 5) and 6).
5) Lift the washer tank, and then disconnect the connector from headlight washer motor. Disconnect washer hoses.
WW-00098
6) Disconnect the washer hose from the motor, and then detach the washer tank.
WW-00012
D: ASSEMBLY
1) Assemble in the reverse order of disassembly.
2) Confirm that water does not leak from installation area of motor.
E: INSPECTION
Apply battery voltage to the connector terminal of the washer motor and make sure the motor operates.
WW-00013
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.0 N·m (0.61 kgf-m, 4.4 ft-lb)
WW-00099
WW-11
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.
Front Wiper 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.
(A)
WW-00048
Tightening torque:
Refer to COMPONENT in General Description.
<Ref. to WW-2, FRONT WIPER, COMPO-
C: ADJUSTMENT
Operate the wiper once. Align the wiper blade to ceramic print point mark (A) of front window panel.
(A)
WW-00048
WW-12
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.
WIPER AND WASHER SYSTEM
6) Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Description.
<Ref. to WW-2, FRONT WIPER, COMPO-
C: INSPECTION
1) When the battery is connected to wiper motor connectors and confirm that motor operates at low speed.
3 2
5 4
1
WW-00050
5) Loosen the bolts and nuts to remove motor.
3 2
5 4
1
WW-00051
B: INSTALLATION
1) Install the wiper link to the vehicle, and then connect 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.
WW-00225
3) Connect the battery to terminals of connector, and remove the terminal connection with motor rotated at low speed, and stop the wiper motor through operation.
3 2
5 4
1
(A)
WW-00224
2) When the battery is connected to terminal of connectors and confirm that motor operates at high speed.
(B)
WW-00226
WW-00052
WW-13
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 operates at low speed again.
3 2
5 4
1
WW-00227
WW-14
Front Washer Nozzle
8. Front Washer Nozzle
A: REMOVAL
1) Remove the washer hose from the washer nozzle.
2) Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle.
WIPER AND WASHER SYSTEM
WW-00023
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
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-15
WIPER AND WASHER SYSTEM
9. Rear Wiper Arm
A: REMOVAL
1) Remove the wiper arm cover (A).
Rear Wiper Arm
C: ADJUSTMENT
1) Operate the rear wiper once.
2) Align the blade to the center of rear defogger heat wire (A).
WW-00191
2) Loosen the nut to remove wiper arm.
WW-00200
WW-00192
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).
WW-00200
Tightening torque:
Refer to COMPONENT in General Description.
<Ref. to WW-3, REAR WIPER, COMPONENT,
WW-16
10.Rear Wiper Motor
Rear Wiper Motor
WIPER AND WASHER SYSTEM
C: INSPECTION
1) Connect the battery to wiper motor connector and confirm that the wiper motor operates.
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.
2 1
4 3
WW-00027
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 assembly (A).
WW-00030
2) Connect the battery to terminal of connector and remove the terminal connections with motor rotated, and stop the wiper motor through operation.
2 1
4 3
WW-00031
3) Connect the battery and confirm that the motor stops at automatic stop position after the motor operates at low speed again.
WW-00028
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.
2 1
4 3
WW-00032
WW-00029
Tightening torque:
Refer to COMPONENT in General Description.
<Ref. to WW-3, REAR WIPER, COMPONENT,
WW-17
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 nozzle.
3) Push the anchor portion of washer nozzle with a thin screwdriver or other tool, and remove the washer nozzle.
WW-00201
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 injection position as shown in the figure.
Injection position:
A: 35 mm (1.38 in)
B: 72
°
(1)
A
B
WW-00054
(1) Nozzle
WW-18
12.Wiper Control Relay
Wiper Control Relay
WIPER AND WASHER SYSTEM
3) Measure the voltage when the wiper relay is operated.
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the right quarter lower trim. <Ref. to EI-
45, REMOVAL, Rear Quarter Trim.>
3) Loosen the nut to remove control unit.
(A) (B)
(C)
(D)
(E)
(F)
WW-00034
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Disconnect the connector from the wiper control relay.
2) Connect the positive (+) lead from the battery to terminal 8 and the negative (
−) lead to terminal 6.
Connect the positive (+) lead from the voltmeter to terminal 3 and the negative (
−) lead to ground.
WW-00055
(A) Switch position
(B) Voltage
(C) ON
(D) 12 V
(E) 0 V
(F) 9
±2 sec.
If operation is not as specified, replace the switch.
4 3
8 7
2 1
6 5
WW-00035
WW-19
Headlight Washer
WIPER AND WASHER SYSTEM
13.Headlight Washer
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.>
4) Draw out headlight washer hose.
5) Disconnect hose (A) from valve (B).
NOTE:
Washer fluid may drain from valve. Put a pan under the valve, then disconnect valve from hose while pinching the hose edge.
B: INSTALLATION
Install in the reverse order of removal.
(A)
(A)
(B)
6) Remove nozzle cover (A).
(A)
WW-00102
WW-00109
7) Push the three pawls to remove outer nozzle (A).
Then pull out inner nozzle (B).
NOTE:
Before pushing the outer nozzle pawls, cover the bumper to avoid scratches.
(A)
(B)
WW-00110
WW-20
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