2004 SUBARU FORESTER roof

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

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

SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
Page
1. General Description ....................................................................................2
2. Sunroof Control System ..............................................................................4
3. Sunroof Lid ..................................................................................................5
4. Sunroof Assembly .......................................................................................6
5. Sunroof Motor .............................................................................................8
6. Sunroof Switch ............................................................................................9

SR-2
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
General Description
1. General Description
A: COMPONENT
(1) Sunroof lid (7) Harness (13) Shim
(2) Rear drain ASSY (8) Sunshade
(3) Frame ASSY (9) GarnishTightening torque: N·m (kgf-m, ft-lb)
(4) Motor ASSY (10) Frame bracketT: 7.4 (0.75, 5.4)
(5) Drive unit (11) Cover
(6) Drain tube (12) Deflector
SR-00013
T
T
T
T
(1)
(2)
(3)
(4)(5)
(6)
(7)
(12)(13)
(11)
(6)(10)(8)
(9)

SR-3
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
General Description
B: CAUTION
 Before disassembling or reassembling parts, always
disconnect battery ground cable. When replacing ra-
dio, control module and other parts provided with
memory functions, record memory contents before dis-
connecting the battery ground cable. Otherwise, the
memory will be erased.
 Reassemble in reverse order of disassembly, un-
less otherwise indicated.
 Adjust parts to the given specifications.
 Connect connectors and hoses securely during
reassembly.
 After reassembly, make sure functional parts op-
erate smoothly.
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance and
voltage.

SR-4
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
Sunroof Control System
2. Sunroof Control System
A: WIRING DIAGRAM
1. SUNROOF

B: INSPECTION
Symptom Checking order
Water leaks. (1) Check roof panel and sunroof lid for improper or poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
Booming noise (1) Check sunroof lid and roof panel for improper clearance.
(2) Check sunshade and roof trim for improper clearance.
Abnormal motor noise (1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cables for wear.
(4) Check cable pipe for deformities.
Failure of sunroof
(Motor operates properly.)(1) Check guide rail for foreign particles.
(2) Check guide rail for improper installation.
(3) Check parts for mutual interference.
(4) Check cable slider for improper clinching.
(5) Check cable for improper installation.
(6) Check clutch adjusting nut for improper tightness.
Motor does not rotate or rotates improperly. (1) Check fuse for blow-out.
(2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check relay for improper operation.
(5) Check poor grounding system.
(6) Check harness for open or short and terminals for poor connections.
(7) Check limit switch for improper operation.

SR-5
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
Sunroof Lid
3. Sunroof Lid
A: REMOVAL
1) Completely close sunroof lid and open sunshade.
2) Detach the four covers (A) and then remove eight
nuts.
3) Carefully remove sunroof lid.
B: INSTALLATION
Install in the reverse order of removal.
C: ADJUSTMENT
1. ALIGNMENT OF HEIGHT BETWEEN
SUNROOF LID AND ROOF PANEL
Loosen sunroof lid nuts and then adjust height by add-
ing (max: four pieces) or extracting (min: zero piece)
shims (standard: two pieces) between sunroof lid and
roof panel.
Difference in height between sunroof lid and
roof panel
2.0
±1.0 mm (0.079±0.039 in)
SR-00002
(A) Shim
(B) Sunroof lid
(C) Roof panel
SR-00003
2.0 1.0 mm (0.079 0.039 in)
(B) (C)
(A)

SR-6
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
Sunroof Assembly
4. Sunroof Assembly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove roof trim. Roof Trim.>
3) Remove sunroof lid. Sunroof Lid.>
4) Disconnect the four drain tubes (A) from sunroof
frame.
5) Disconnect sunroof harness connector.
6) Remove the bolts, and then remove the frame
bracket.
7) Remove bolts and nuts and then detach sunroof
frame.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be careful not to snag harness.
NOTE:
 Make sure to connect harness connector.
 When installing drain tube, insert it securely into
drain pipe.
Length A:
15 mm (0.59 in) or more
C: DISASSEMBLY
1) Remove sunroof frame.
2) Cut the pawl (A) of front sunshade RH.
3) Remove the front slider RH.
4) Pull out the sunshade (B) from sunroof frame.
D: ASSEMBLY
Assemble in the reverse order of disassembly.
SR-00014
SR-00015(A)(A)
SR-00005
A
SR-00006
(A)
SR-00007