2004 SUBARU FORESTER torque

EB-6
EXTERIOR BODY PANEL
General Description
4. REAR DOOR PANEL
(1) Weather strip (8) Rear sashTightening torque: N·m (kgf-m, ft-lb)
(2) Stabilizer (Outer) (9) Lower hingeT1: 7.5 (0.76, 5.5)
(3) Stabilizer (Inner) (10) Upper hingeT2: 25 (2.5, 18)
(4) Door panelT3: 30 (3.1, 18)
(5) CheckerT4: 33 (3.4, 24)
(6) Sealing coverT5: 14 (1.4, 10.3)
(7) Front sashT6: 1.5 (0.15, 1.1)
EB-00174
T1
T6
T1(1)
(3)
(7)
T2
T2
T6
T5
T3
T4T3(10)(4)
(5)
(6)
(9)
T5
(8)
(2)
T5T5

EB-7
EXTERIOR BODY PANEL
General Description
5. REAR GATE PANEL
(1) Damper stay (3) Rear gateTightening torque: N·m (kgf-m, ft-lb)
(2) Hinge (4) Rear gate garnishT1: 7.5 (0.76, 5.5)
T2: 14 (1.4, 10.1)
T3: 25 (2.5, 18.1)
EB-00037
T1
(2)
(3)
(4) (1)
T2
T3
T1
T1
T1

EB-9
EXTERIOR BODY PANEL
Front Hood Panel
2. Front Hood Panel
A: REMOVAL
1) Open the front hood to remove washer nozzles.
2) Release the clips to remove front hood insulator.
3) Remove the bolts to remove front hood from hinges.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the clearance between front hood panel
and front fender panel. Clearance must be equal at
both sides.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
C: ADJUSTMENT
1) Use the hinge mounting holes to align the front
hood longitudinally and laterally.
2) Adjust the height at front end of hood. SL-33, ADJUSTMENT, Front Hood Lock Assem-
bly.>3) Rotate the hood buffer to adjust lateral height.
EB-00008
EB-00009
EB-00009
EB-00010

EB-10
EXTERIOR BODY PANEL
Front Fender Panel
3. Front Fender Panel
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the front bumper face. REMOVAL, Front Bumper.>
3) Remove the mud guard. MOVAL, Mud Guard.>
4) Remove the side sill spoiler. MOVAL, Side Sill Spoiler.>
5) Remove the side protector. MOVAL, Side Garnish.>
6) Loosen the bolts and clip to remove front fender
panel.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When the front fender panel is installed, clear-
ance between front fender panel and front hood
panel must be equal.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.5 ft-lb)
EB-00011

EB-11
EXTERIOR BODY PANEL
Front Door Panel
4. Front Door Panel
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the front door trim. MOVAL, Front Door Trim.>
3) Remove the outer mirror assembly. GW-12, REMOVAL, Outer Mirror Assembly.>
4) Remove the front sealing cover. REMOVAL, Front Sealing Cover.>
5) Remove the front door glass. REMOVAL, Front Door Glass.>
6) Remove the front door regulator and motor. to GW-21, REMOVAL, Front Regulator and Motor
Assembly.>
7) Remove the front door latch assembly. SL-24, REMOVAL, Front Door Latch Assembly.>
8) Remove the front outer handle. REMOVAL, Front Outer Handle.>
9) Remove the front pillar lower trim to disconnect
the connector from body harness.
10) Put a wooden block on jack and place jack under
door. Support the door with a jack to protect it from
damage.
NOTE:
When supporting the door with a jack, be careful
not to deform the door hinges while working.11) Remove the checker bolts.
12) Remove the door-side bolts for upper and low-
er hinges to remove the front door panel.
13) Using the ST, remove the body-side bolts for
upper and lower hinges, and remove door hinges.
ST 925610000 WRENCH
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to the sliding area of door hinges.
3) Refer to COMPONENT in General Description for
tightening torque. EL, COMPONENT, General Description.>
EB-00012
EB-00013
EB-00014
EB-00015
EB-00016
ST

EB-14
EXTERIOR BODY PANEL
Rear Door Panel
6. Rear Door Panel
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the rear door trim. MOVAL, Rear Door Trim.>
3) Remove the rear sealing cover. REMOVAL, Rear Sealing Cover.>
4) Remove the rear door glass. REMOVAL, Rear Door Glass.>
5) Remove the rear door regulator and motor as-
sembly. tor and Motor Assembly.>
6) Remove the rear door latch assembly. SL-28, REMOVAL, Rear Door Latch Assembly.>
7) Remove the rear outer handle. REMOVAL, Rear Outer Handle.>
8) Remove the center pillar lower trim. 44, REMOVAL, Lower Inner Trim.>
9) Remove the seat belt bracket and blind plug.
Disconnect the connector of door harness and re-
move the door hinge nut.
10) Put a wooden block on the jack and place the
jack under the door. Support the door with the jack
to protect it.
NOTE:
When supporting the door with a jack, be careful
not to deform the door hinges while working.11) Remove the checker bolts.
12) Remove the door-side bolts for upper and low-
er hinges to remove the rear door panel.
13) Using the ST, remove the body-side bolts for
upper and lower hinges, and remove door hinges.
ST 925610000 WRENCH
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to the sliding area of door hinges.
3) Refer to COMPONENT in General Description for
tightening torque. PANEL, COMPONENT, General Description.>
C: ADJUSTMENT
1) Using the ST, loosen the body-side bolts of up-
per and lower hinges to align the position of rear
door panel longitudinally and vertically.
ST 925610000 WRENCH
EB-00019
EB-00013
EB-00014
EB-00015
EB-00016
ST

EB-18
EXTERIOR BODY PANEL
Rear Gate Panel
2. REAR GATE DAMPER STAY
1) Open the rear gate. Use a support to support the
rear gate.
NOTE:
After the rear gate damper stay is removed, the rear
gate cannot stay open. Supporting the rear gate with
a jack, remove the bolts.
CAUTION:
 Do not damage the piston rods and oil seals.
 Never disassemble the cylinders: They con-
tain gas.
2) Loosen the bolts to remove the rear gate damper
stay from rear gate.
B: INSTALLATION
1. REAR GATE PANEL
1) Install in the reverse order of removal.
2) Install the rear gate panel with uniform clearance
to the body.
3) Refer to COMPONENT of General Description for
tightening torque. EL, COMPONENT, General Description.>
NOTE:
After supporting the rear gate with a jack, start
working.
2. REAR GATE DAMPER STAY
1) Install the mounting bolt (A) to the rear gate pan-
el and body.
Tightening torque:
14 N·m (1.43 kgf-m, 10.3 ft-lb)
2) Firmly install the rear gate damper stay (B) to
mounting bolt (A).
3) Tighten the bolts at upper side of rear gate damp-
er stay.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
EB-00021
EB-00024
(A)(B)
EB-00075

CC-5
CRUISE CONTROL SYSTEM
Actuator
2. Actuator
A: REMOVAL
CAUTION:
 Be careful not to apply excessive load to the
wire cable when adjusting and/or installing; oth-
erwise, the actuator may be deformed or dam-
aged.
 Do not bend the cable sharply with a radius
less than 100 mm (3.94 in); otherwise, cable
may bend permanently, resulting in poor per-
formance.
 When installing the cable, be careful not to
sharply bend or pinch the inner cable; other-
wise, the cable may break.
1) Disconnect the ground cable from battery.
2) Remove the clip bands from cruise control cable.
3) Loosen the nut which secures cruise control ca-
ble end to throttle cam, and then remove the cable
from throttle cam.
4) Remove the four actuator attaching bolts.
5) Remove the actuator while disconnecting the
connector.
 LHD model RHD model
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
ACTUATOR:
7.4 N
⋅m (0.75 kgf-m, 5.4 ft-lb)
Cable end nut:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
NOTE:
(A): Must be adjusted when the cable end outer is
fixed in place, so that gap between throttle cam and
lever is 0 — 1 mm (0 — 0.04 in), otherwise, inner
cable deflection (D) is 1 — 8 mm (0.039 — 0.315 in)
when the throttle cable is installed.
(Must be attached while the throttle cam is being
pulled by wire cable.)
(B): Must be coated evenly on the cam end inner
connection.
(C): Cover must be inserted securely, until tip of ca-
ble touches cover stopper.
CC-00009
CC-00010
CC-00070
CC-00037
(B)
(A) (D) (C)