1999 SUBARU FORESTER Service Repair Manual

1. Hood
A: REMOVAL AND INSTALLATION
NOTE:
The hood lock has a dual locking design which
consists of a main lock and a safety lock mecha-
nism. When the release knob located at the front
pillar on the driver's side is pulled back, the main
lock is released through the cable attached to the
knob.
The safety lock can be released by pushing the
lever protruding above the front grill while opening
the hood.
1. HOOD
1) Open front hood, and remove washer hose.
2) Remove attaching bolts.
G5M0137
3) Detach front hood from hinges.
4) Install in the reverse order of removal.
CAUTION:
Adjust buffer assembly on each end so that
main lock is applied securely when hood is
released from a height of approx. 20 mm (0.79
in).
NOTE:
Align the center of striker with lock during installa-
tion. Make sure safety lever is properly caught by
the striker under the hood's own weight.
G5M0141
2. HOOD LOCK
1) Open front hood and remove front grille. to 5-1 [W12A0].>
2) Remove bolts which secure lock assembly to
radiator panel, and remove lock assembly.
S5M0148
3) Disconnect release cable from lock assembly.
4) Install in the reverse order of removal.
NOTE:
IRoute hood lock release cable and hold with
clips.
IAfter installing release cable, ensure that it oper-
ates smoothly.
IApply grease to sliding surfaces of parts.
G5M0142
29
[W1A2]5-1SERVICE PROCEDURE
1. Hood

3. RELEASE CABLE
1) Remove front grille.
2) Remove release cable from lock assembly.

3) Remove cable clip from engine compartment.
4) While disengaging cable from opener lever,
remove opener lever from front pillar.
S5M0149
5) Remove release cable.
6) Install in the reverse order of removal.
B: POINTS TO CHECK
1) Check striker for bending or abnormal wear.
2) Check safety lever for improper movement.
3) Check other levers and spring for rust formation
and rough movement.
G5M0140
C: ADJUSTMENT
1) Fore-aft and left-right adjustments
Loosen striker mounting bolts and adjust fore-and-
aft position of striker.
CAUTION:
Do not adjust striker position using the lock.
Doing so may result in a misaligned front grille.
G5M0143
2) Up-down adjustment
Make up-and-down adjustment of striker only
when hood does not properly contact buffer or
hood is not flush with fender, or when release cable
does not properly operate. Adjustment can be
made by adjusting the stroke length of the striker
after lock assembly mounting screws are removed.
30
5-1[W1A3]SERVICE PROCEDURE
1. Hood

2. Fuel Flap
A: REMOVAL AND INSTALLATION
1. FUEL FLAP
1) Remove bolts which hold hinge to vehicle body,
and detach fuel flap and hinge as a unit.
S5M0150
2) Install in the reverse order of removal.
CAUTION:
Make sure the clearance between the fuel flap
and vehicle body is equal at all points.
2. FUEL FLAP OPENER
1) Remove driver's seat and rear seat cushion.
2) Turn over the floor mat (driver's side).
3) Remove all clips which hold cable.
4) Disconnect cable (A) from pull handle (B).
5) Detach pull handle by removing bolts.
S5M0291B
6) Detach fuel lock holder by turning it.
7) Install in the reverse order of removal.
CAUTION:
After installing opener cable, ensure it moves
smoothly.
3. Front Bumper
A: REMOVAL AND INSTALLATION
1) Disconnect the ground cable from the battery.
2) Remove front fog light.
3) Remove the front grille.
4) Remove the extension of both sides.
S5M0152A
5) Remove the seven clips and then detach plate
(A).
S5M0397A
6) Remove under cover.
7) Remove the seven clips from under side of
bumper.
S5M0153
31
[W3A0]5-1SERVICE PROCEDURE
3. Front Bumper

2. Fuel Flap
A: REMOVAL AND INSTALLATION
1. FUEL FLAP
1) Remove bolts which hold hinge to vehicle body,
and detach fuel flap and hinge as a unit.
S5M0150
2) Install in the reverse order of removal.
CAUTION:
Make sure the clearance between the fuel flap
and vehicle body is equal at all points.
2. FUEL FLAP OPENER
1) Remove driver's seat and rear seat cushion.
2) Turn over the floor mat (driver's side).
3) Remove all clips which hold cable.
4) Disconnect cable (A) from pull handle (B).
5) Detach pull handle by removing bolts.
S5M0291B
6) Detach fuel lock holder by turning it.
7) Install in the reverse order of removal.
CAUTION:
After installing opener cable, ensure it moves
smoothly.
3. Front Bumper
A: REMOVAL AND INSTALLATION
1) Disconnect the ground cable from the battery.
2) Remove front fog light.
3) Remove the front grille.
4) Remove the extension of both sides.
S5M0152A
5) Remove the seven clips and then detach plate
(A).
S5M0397A
6) Remove under cover.
7) Remove the seven clips from under side of
bumper.
S5M0153
31
[W3A0]5-1SERVICE PROCEDURE
3. Front Bumper

8) Turn over the front mud guard of the front por-
tion and then remove bolt.
S5M0154
9) Remove bumper face and E/A foam.
10) Remove the four bolts and then detach the
back beam.
S5M0398
11) Remove the four bolts and then detach the
beam upper.
S5M0156
12) Install in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing the bumper.
4. Rear Bumper
A: REMOVAL AND INSTALLATION
1) Disconnect the ground cable from the battery.
2) Open rear gate.
3) Remove the five screws and the clip from the
rear bumper.
S5M0399
4) Disconnect license plate light connector.
5) Remove bolts and clips from under side of
bumper.
S5M0157
6) Remove bumper face and E/A foam.
7) Remove canister.
8) Remove bolts from bumper stay.
G5M0161
9) Remove rear bumper beam.
10) Install in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.
32
5-1[W4A0]SERVICE PROCEDURE
4. Rear Bumper

8) Turn over the front mud guard of the front por-
tion and then remove bolt.
S5M0154
9) Remove bumper face and E/A foam.
10) Remove the four bolts and then detach the
back beam.
S5M0398
11) Remove the four bolts and then detach the
beam upper.
S5M0156
12) Install in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing the bumper.
4. Rear Bumper
A: REMOVAL AND INSTALLATION
1) Disconnect the ground cable from the battery.
2) Open rear gate.
3) Remove the five screws and the clip from the
rear bumper.
S5M0399
4) Disconnect license plate light connector.
5) Remove bolts and clips from under side of
bumper.
S5M0157
6) Remove bumper face and E/A foam.
7) Remove canister.
8) Remove bolts from bumper stay.
G5M0161
9) Remove rear bumper beam.
10) Install in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.
32
5-1[W4A0]SERVICE PROCEDURE
4. Rear Bumper

5.
A:
ProcessNo. Process
1 Set
paint
bumper
G5M0164
2
Mask
Nichiban
3 Degreasing,
cleaning Clean
etc.
4
5 Dry
In
Therefore,
6 Solid
Use
I Paint
Solid
Hardener
Thinner
I Mixing
Main
I V
I Film
I Spraying
\(2.5
2, Use
I
Paint
Metallic
Hardener
Thinner
I Mixing
Main
I V
I Film
I Spraying
\(2.52,
7 Dry
20\311C
In
8 Apply
\(I\),
t5\3207minutes
I Paint
Metallic
Hardener
Thinner
I Mixing
I V
I Film
I Spraying
\(2.5
2,
9 60\311C
If
\(176\311F\).
10 1
33
[W5A0]5-1SER
5.

6. Repair Instructions for Colored PP Bumper
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be
restored to its former condition. Damage limited to shallow scratches that cause only a change in the lus-
tre of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain
this point to the customer and obtain his or her understanding. Repair methods are outlined below, based
on a classification of the extent of damage.
A: MINOR DAMAGE CAUSING ONLY A CHANGE IN THE LUSTRE OF THE
BUMPER DUE TO A LIGHT TOUCH
Almost restorable.
Process
No.Process name Job contents
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sand paper in a ªfeatheringº motion.
3 FinishResin section Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recom-
mended wax: NITTO KASEI Soft 99 TIRE
WAX BLACK, or equivalent.Perform either the same operation as for the
resin section or process No. 18 and subse-
quent operations in the ª(3)º section, depend-
ing on the degree and nature of damage.
Polish the waxed area with a clean cloth after
5 to 10 minutes.
B: DEEP DAMAGE CAUSED BY SCRATCHING FENCES, ETC.
A dent cannot be repaired but a whitened or swelled part can be removed.
Process
No.Process name Job contents
1 Cleaning Clean damaged area with water.
2Removal of dam-
aged areaCut off protruding area, if any, due to collision, using a putty knife.
3 Sanding Grind the affected area with #100 to #500 sand paper.
4 FinishResin section Coated section
Same as Process No. 3 in the ª(1)º section.Perform Process No. 12 and subsequent
operations in the ª(3)º section.
34
5-1[W600]SERVICE PROCEDURE
6. Repair Instructions for Colored PP Bumper