1999 SUBARU FORESTER Service Repair Manual

7. Door Lock Assembly
A: FRONT DOOR
S5M0179A
(1) Inner remote ASSY
(2) Bell crank
(3) Door outer handle
(4) Striker(5) Door latch
(6) Auto-door lock actuatorTightening torque: N´m (kg-m, ft-lb)
T1:
6.4±2.0 (0.65±0.2, 4.7±1.4)
T2:7.4±2.0 (0.75±0.2, 5.4±1.4)
T3:18±4 (1.8±0.4, 13.0±2.9)
9
[C7A0]5-2COMPONENT PARTS
7. Door Lock Assembly

B: REAR DOOR
S5M0180A
(1) Door outer handle
(2) Door latch
(3) Auto-door lock actuator
(4) Striker(5) Rod holder
(6) Inner remote ASSYTightening torque: N´m (kg-m, ft-lb)
T1:
6.4±2.0 (0.65±0.2, 4.7±1.4)
T2:7.4±2.0 (0.75±0.2, 5.4±1.4)
T3:18±4 (1.8±0.4, 13.0±2.9)
10
5-2[C7B0]COMPONENT PARTS
7. Door Lock Assembly

8. Door Trim
S5M0382A
(1) Gusset cover
(2) Weatherstrip
(3) Trim panel(4) Pull handle
(5) Handle
(6) Pocket(7) Speaker grille
11
[C800]5-2COMPONENT PARTS
8. Door Trim

9.
S5M0182A
\(1\)
\(2\)\(3\)
\(4\)\(5\)
12
5-2[C900]COMPONENT
9.

1.
A:
NOTE:
This
details,
H5M0910A
13
[W1A0]5-2SER
1.

2. Door
A: REMOVAL AND INSTALLATION
1. DOOR ASSEMBLY
1) Remove front pillar lower trim [W5A1].> and disconnect connectors from body
harness.
B5M0726
2) Place a cloth or a wood block under door to
prevent damage, and support it with a jack.
3) Remove checker bolt.
Tightening torque:
32
±10 N´m (3.3±1.0 kg-m, 23.9±7.2 ft-lb)
S5M0183
4) Remove bolts (M8) securing upper and lower
hinges to door, and remove door from hinges.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
5) Remove hinges by loosening hinges mounting
bolt (M8) off of body.
Tightening torque:
29
±5 N´m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
CAUTION:
Work carefully to avoid damaging door.
G5M0385
6) Install in the reverse order of removal.
NOTE:
Apply grease to moving parts of door hinges.
14
5-2[W2A1]SERVICE PROCEDURE
2. Door

2. TRIM PANEL
CAUTION:
Be careful not to break clip by applying undue
force.
1) Front door trim:
(1) Remove gusset cover (A), power window
switch assembly (B) and pocket (C).
(2) Remove screws and then disengage the
clips.
(3) Detach trim panel and then disconnect con-
nector.
(4) Install in the reverse order of removal.
2) Rear door trim:
(1) Remove handle (E), pocket (F) and clips
(G).
(2) Remove screws and then disengage the
clips.
(3) Detach trim panel and then disconnect con-
nector.
(4) Install in the reverse order of removal.
S5M0383A
3. SEALING COVER
1) Remove trim panel.
2) Remove speaker, trim bracket, remote assem-
bly and disconnect connectors.
3) Remove sealer with a spatula.
CAUTION:
Be careful because cover may break if sealer is
removed forcefully.
G5M0391
4) Install in the reverse order of removal.
NOTE:
IConfirm that sealer is properly applied without
breaks. Then install sealing cover.
IWhen repairing or replacing sealing cover, use
ªCEMEDINE 5430Lº as sealer. It may be overlaid
on existing sealer.
Sealer:
CEMEDINE 5430L
CAUTION:
IAny breaks in sealer can cause water leak-
age or entry of air and dust. Be sure sealer is
applied in a continuous line.
IMake sure sealing cover bonded areas are
free from wrinkles or openings.
15
[W2A3]5-2SERVICE PROCEDURE
2. Door

4. CHECKER
1) Completely close door glass.
2) Remove trim panel.
3) Remove sealing cover.
4) Remove attaching bolt to body.
5) Loosen two nuts securing checker, and take out
checker through access hole in underside.
S5M0363A
6) Install in the reverse order of removal.
Tightening torque:
T1: 7.5
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4
ft-lb)
T2: 32
±10 N´m (3.3±1.0 kg-m, 23.9±7.2
ft-lb)
5. INNER REMOTE
1) Remove trim panel.
2) Remove sealing cover.
3) Disconnect joints of two rods.
4) Unlatch rod holder.
5) Remove inner remote assembly.
S5M0186
6) Install in the reverse order of removal.
NOTE:
If rear door is equipped with child safety lock,
check that child lock lever moves without dragging.
6. DOOR LATCH AND OUTER HANDLE
1) Completely close door glass.
2) Remove door trim panel.
3) Remove inner remote assembly.
4) Remove sealing cover around latch service
hole.
5) Remove latch and actuator assembly (A):
(1) Turn rod holder to disconnect joint between
key lock and rod.
(2) Turn rod holder to disconnect joint between
outer handle and rod.
(3) Turn rod holder to disconnect joint between
crank and rod.
(4) Loosen screws securing both latch and
actuator, then remove latch and actuator
assembly through service hole in bottom.
S5M0189A
(5) Install in the reverse order of removal.
Tightening torque (screw):
6.4
±2.0 N´m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
NOTE:
ICheck operation of each part.
ICheck each sliding part for proper lubrication.
CAUTION:
After installation, be sure lock mechanism
operates normally.
16
5-2[W2A4]SERVICE PROCEDURE
2. Door