1999 SUBARU FORESTER Service Repair Manual

C: INSPECTION
1. FRONT DOOR GLASS
1) Close front door and check all clearances.
S5M0203A
2) If any clearance is not correct, adjust affected
parts. Re-check that all clearances are correct.
CAUTION:
IRepeatedly adjust parts until all clearances
are correct.
IAfter clearance adjustment, make sure that
all adjusting bolts and nuts are tightened.
2. REAR DOOR GLASS
1) Close rear door and check all clearances.
S5M0204A
2) If any clearance is not correct, adjust affected
parts. Re-check that all clearances are correct.
CAUTION:
IRepeatedly adjust parts until all clearances
are correct.
IAfter clearance adjustment, make sure that
all adjusting bolts and nuts are tightened.
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[W2C2]5-2SERVICE PROCEDURE
2. Door

3. Rear Gate
A: REMOVAL AND INSTALLATION
CAUTION:
IBe careful not to scratch coated surfaces of
vehicle body and window glass during
removal. Place a cloth over the affected area.
IBe careful not to damage trim panels.
IUse an assistant when handling heavy parts.
IBe careful not to damage or lose small parts.
1. REAR GATE ASSEMBLY
1) Remove rear gate inner handle (A) from rear
gate and then detach trim panel.
CAUTION:
Be careful not to damage clips or their holes.
S5M0386A
2) Disconnect connectors and terminal.
3) Disconnect rear washer hose from wiper motor.
4) If disconnected harness is re-used, tie connec-
tor with a string and place on the upper side of rear
gate for ready use.
CAUTION:
Do not forcefully pull cords, lead wires, etc.
since damage may result; carefully extract
them in a wavy motion while holding connec-
tors.
5) Remove both rubber ducts and then extract
washer hose and harness connector.
6) Gas stay:
(1) Completely open rear gate.
(2) Remove bolts which hold gas stay to rear
gate.
CAUTION:
IBe careful because rear gate drops while
removing bolts. Have an assistant support it
while removing bolts.
IBe sure to place a folded cloth between rear
gate and body to prevent scratches.7) Remove the bolts which hold rear gate to hinge
and then detach rear gate.
S5M0206
8) General precautions in handling rear gate gas
stay are as follows.
CAUTION:
IDo not attempt to disassemble gas stay
because its cylinder is filled with gas.
IBefore discarding gas stay, place it at a
slight angle with the cylinder body side facing
up and drilla2to3mm(0.08 to 0.12 in) dia.
hole to completely discharge the content. (Gas
is odorless, colorless and harmless; however,
metal powder may come out of the hole.)
G5M0551
IIt is good practice to place a vinyl sack over
it before drilling the hole because oil may spurt
out. Be careful to prevent the vinyl cover from
becoming entangled on the drill.
G5M0491
IBe careful not to scratch the exposed sec-
tion of piston rod or allow oil or paint to come
in contact with it.
26
5-2[W3A0]SERVICE PROCEDURE
3. Rear Gate

IDo not attempt to rotate the extended piston
rod.
9) Install in the reverse order of removal.
CAUTION:
IBe careful not to mistake RH and LH body
side buffers.
IBe sure to add sealer to hinge.
IWhen installing rear gate, be careful not to
damage coating on body and rear gate.
2. LATCH
1) Remove trim panel.
2) Disengage rod (latch to link) from latch (A).
3) Disengage rod (latch to outer handle) from
outer handle (B).
4) Remove bolts from latch (A).
S5M0387A
5) Disconnect rear gate switch connector from
latch (A).
6) Detach latch.
7) Install in the reverse order of removal.
CAUTION:
Firmly join latch with rod (to key cylinder) and
outer handle.
3. OUTER HANDLE
1) Remove trim panel.
2) Disconnect rod (latch to outer handle) from
outer handle (B).
3) Remove the four nuts used to hold outer handle
(B) to the inside of rear gate, and detach outer
handle.
CAUTION:
Be careful not to damage packing when remov-
ing outer handle.
S5M0387A
4) Install in the reverse order of removal.
CAUTION:
Completely insert latch pin into handle lever.
4. KEY CYLINDER
1) Remove trim panel.
2) Remove actuator (E).
3) Disengage rod from key cylinder (C).
4) Remove retaining spring from key cylinder (C),
and detach key cylinder from outside.
S5M0387A
5) Install in the reverse order of removal.
27
[W3A4]5-2SERVICE PROCEDURE
3. Rear Gate

5. STRIKER
1) Remove rear skirt trim.
2) Remove the two bolts from striker (D) and
detach striker.
S5M0387A
3) Install in the reverse order of removal.
6. WEATHERSTRIP
1) Place weatherstrip so that its joints meet at
lower center of vehicle body, and install by insert-
ing flanged portion from below, as shown in section
AÐA in the figure.
G5M0492
2) Tap along entire length with a rubber hammer to
firmly insert body flange into weatherstrip.
CAUTION:
IBe careful not to install in wrong direction.
IInstall weatherstrip carefully and firmly.
G5M0493
28
5-2[W3A5]SERVICE PROCEDURE
3. Rear Gate

4.
A:
H5M0914A
1.
Description
Repair
I Cartridge
I Primer Sunstar
Sunstar
Windshield
Sealant
Suction
Putty
Sponge
Gauze
Alcohol
T
29
[W4A1]5-2SER
4.

5. Windshield
A: REMOVAL
1. USING WINDSHIELD KNIFE
The following procedure for the front windshield
can also be applied to other window glass.
1) Remove wiper arm and cowl panel.
2) Remove front side molding and upper front
molding.
3) Remove glass:
(1) Put protective tape on body to prevent dam-
age.
(2) Apply soapy water to the surface of the
adhesive agent so the knife blade slides
smoothly.
(3) Cut off excess adhesive agent.
(4) Put windshield knife into layer of adhesive.
(5) Cut adhesive layer with the windshield
knife.
CAUTION:
IKeep knife edge along glass surface and end
face.
IWhen first putting knife into layer of
adhesive, select point with wide gap between
body and glass.
G5M0418
NOTE:
A matching pin is cemented to corners of glass on
compartment side.
Use a piano wire when cutting each pin.
G5M0412
2. USING PIANO WIRE
1) Remove wiper arm and cowl panel.
2) Remove roof molding and upper front window
molding.
3) Remove glass:
(1) Put protective tape on body to prevent dam-
age.
(2) Using drill or putty knife, make through-hole
(one place) in adhesive agent.
(3) Pass piano wire through the hole from
inside the compartment, and connect both ends
of wire securely to wooden blocks.
G5M0494
(4) Cut adhesive layer with the wire by pulling
it back and forth.
CAUTION:
When making through-hole into adhesive layer
and cutting the adhesive, be careful not to
damage interior and exterior parts.
30
5-2[W5A1]SERVICE PROCEDURE
5. Windshield

B: INSTALLATION
1) After cutting layer of adhesive, remove dam
rubber remaining on body.
2) Finishing adhesion surface on body side:
Using a cutter knife etc., cut layer of adhesive
sticking firmly to body, and finish it to a smooth
surface of about 2 mm (0.08 in) in thickness.
CAUTION:
Take extra care not to cause damage to body
paint.
G5M0553
3) Cleaning body surface:
(1) Thoroughly remove chips, dirt and dust
from body surface.
(2) Clean body wall surface and upper surface
of layer of adhesive with a solvent such as alco-
hol or white gasoline.
4) Positioning glass:
(1) Mount glass on body.
(2) Adjust position of glass so that gap between
body and glass is uniform on all sides.
(3) Put matching pin on body and glass in sev-
eral places.
G5M0407
5) Cleaning glass:
(1) Dismount glass from body.
(2) Clean surface of glass to be adhered with
alcohol or white gasoline.6) Application of primer:
(1) Using a sponge, apply primer to part of
glass to be adhered.
(2) Apply primer to part of body to be adhered.
CAUTION:
IPrimer is hard to wipe off of body paint,
instrument panel, inner trim, etc. So put mask-
ing around these areas for protection.
IAfter application, let 1st primer dry naturally
for about 10 minutes.
IDo not touch primer-coated surface under
any circumstances.
G5M0495
7) Application of adhesive:
(1) Cut nozzle tip of cartridge as shown in fig-
ure.
G5M0408
(2) Open cartridge and put it into a gun with
nozzle attached.
(3) Apply adhesive uniformly to all sides of
adhesion surface while operating gun along
glass end face.
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[W5B0]5-2SERVICE PROCEDURE
5. Windshield

8) Installation of glass:
(1) Hold glass with rubber suction cups.
(2) Mount glass on body with matching pin
aligned.
G5M0409
(3) Stick them fast by pressing all sides lightly.
9) Installation of molding:
(1) Remove adhesive overflowing from outside
of glass until it becomes level with outer height
of glass. Then, add adhesive to portions that
need it, and clean with alcohol or white gaso-
line.
G5M0496
(2) Firstly, press-fit upper front window molding
and lastly, roof molding.
CAUTION:
Do not open and close door after moldings
have been installed. When opening and closing
door for unavoidable reasons, lower door glass
and gently move door.
G5M0417
10) Water leakage test:
Test for water leakage about one hour after instal-
lation.
CAUTION:
IMove vehicle very gently.
IDo not squirt strong hose stream on vehicle.
11) Natural drying:
After completing all operations, leave vehicle alone
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him or her
that vehicle should not be subjected to heavy
shock for at least three days.
12) Install cowl panel and wiper arm.
32
5-2[W5B0]SERVICE PROCEDURE
5. Windshield