2004 SUBARU FORESTER tow

AC-40
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Evaporator
15.Evaporator
A: REMOVAL
1) Perform the refrigerant recovery operation, and
then disconnect the toe board area A/C pipe. to AC-26, OPERATION, Refrigerant Recovery Pro-
cedure.>
2) Remove the glove box.
3) Remove blower motor unit assembly. AC-32, REMOVAL, Blower Motor Unit Assembly.>
4) Loosen the screws and remove evaporator cov-
er.
5) Remove the A/C pipes in unit.
6) Rotate the upper part of evaporator tilt toward
the front vehicle and the lower part tilt toward the in-
terior, respectively. Then pull out the heater case to
the left side.
7) Remove the two bolts to remove expansion
valve.
CAUTION:
If the evaporator is replaced, add appropriate
amount of compressor oil to evaporator. to AC-31, REPLACEMENT, Compressor Oil.>
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Replace the O-ring for A/C pipe with a new one,
and then apply compressor oil.
AC-00867
AC-00868

IDI-10
INSTRUMENTATION/DRIVER INFO
Combination Meter Assembly
3. Combination Meter Assem-
bly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Set the tilt steering at lowest position.
3) Remove the screws and detach meter visor.
4) Remove the screws of combination meter and pull
out the meter toward you.
5) Disconnect the connector in the upper area of
combination meter to remove meter.
CAUTION:
 Be careful not to damage the meter or instru-
ment panel.
 Pay particular attention to avoid damaging
the meter glass.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
 Make sure that electrical connector is connected
securely.
 Make sure that each meter operates normally.
IDI00001
IDI00002

EI-34
EXTERIOR/INTERIOR TRIM
Side Garnish
10.Side Garnish
A: REMOVAL
1) Incise the edge of garnish using cutter, and then
remove the garnish with pulling towards you by
hands.
NOTE:
Remove the garnish carefully. Forced removal of
garnish may damage garnish and clips.
2) Adhere the masking tape around area where the
double-sided tape of side garnish was adhere.
3) Apply the solvent (SUMITOMO 3M 4000 or equiv-
alent) to the area where double-sided tape was ad-
hered.
NOTE:
 Wipe off immediately when the solvent is touched
on the garnish surface.
 Do not use the solvent to the body which repaired
with lacquer paint.
4) Cover the area where the solvent applied using
plastic wrap, and then heat the double-sided tape
was adhered for 5 to 15 minutes in 40 to 60°C (104
to 140°F) using heat lamp.
5) Remove the double-sided tape of side garnish
side tape by following above step 3) and 4).
NOTE:
When the double-sided tape is not removed com-
pletely using above steps, use the scraper.
B: INSTALLATION
1) Apply the PRIMER (SUMITOMO 3M K-500 or
equivalent) widely to the slightly larger area where
double-sided tape was adhered, and then adhere
the double-sided tape (SUMITOMO 3M 5305 or
equivalent).
NOTE:
Use 5 mm (0.2 in) width and 1 mm (0.04 in) thick-
ness double-sided tape.
2) Heat the vehicle body to 40 to 60°C (104 to
140°F) and garnish to 20 to 30°C (68 to 86°F) using
heat lamp.
3) Remove the double-sided tape backing sheet, and
then align the clips to vehicle body holes. Press and
install the side garnish applying 69 — 98 N (7 — 10
kgf, 15 — 22 lbf) by the hands, using care to avoid air
entering.
NOTE:
 To keep the adhesion, do not wash the vehicle
within 24 hours.
 After the adhesion, use care not to move the side
garnish up and down.
C: INSPECTION
 Check the side garnish is not damaged or
cracked.
 Check the clips are not broken.
(1) Double-sided tape
(2) Front side
EI-00109
(1)
(2)
EI-00110
(1)
(2)

EI-35
EXTERIOR/INTERIOR TRIM
Front Door Trim
11.Front Door Trim
A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. Other-
wise the clip may be broken.
1) Disconnect the ground cable from battery.
2) Remove the gusset cover.
3) Pull up the inner remote cover toward you to re-
move upper hook. Pull down it to remove the lower
hook. Remove the inner remote cover.
4) Remove the power window control switch. to GW-7, REMOVAL, Power Window Control
Switch.>
5) Remove the clips of trim panel using clip remov-
er to remove trim panel.
B: INSTALLATION
Install in the reverse order of removal.
EI-00054
EI-00055

EI-36
EXTERIOR/INTERIOR TRIM
Rear Door Trim
12.Rear Door Trim
A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. Other-
wise the clip may be broken.
1) Disconnect the ground cable from battery.
2) Pull up the inner remote cover toward you to re-
move upper hook. Pull down it to remove the lower
hook. Remove the inner remote cover.
3) Remove the power window control switch. GW-7, REMOVAL, Power Window Control Switch.>
4) Remove the clips of trim panel using clip remov-
er to remove trim panel.
B: INSTALLATION
Install in the reverse order of removal.
EI-00054
EI-00098

PC-2
PRECAUTION
Precaution
1. Precaution
A: PRECAUTION
Please clearly understand and adhere to the follow-
ing general precautions. They must be strictly fol-
lowed to avoid minor or serious injury to the person
doing the work or people in the area.
1. ABS
Handle the ABS as a total system. Do not disas-
semble or attempt to repair individual parts. Doing
so could prevent the ABS system from operating
when needed or cause it to operate incorrectly and
result in injury.
2. BRAKE FLUID
If brake fluid gets in your eyes or on your skin, do
the following:
 Wash out your eyes and seek immediate medical
attention.
 Wash your skin with soap and then rinse thor-
oughly with water.
3. RADIATOR FAN
The radiator fan may rotate without warning, even
when the engine is not on. Do not place your hand,
cloth, tools, or other items near the fan at any time.
4. ROAD TESTS
Always conduct road tests in accordance with traf-
fic rules and regulations to avoid bodily injury and
interrupting traffic.
5. AIRBAG
To prevent bodily injury from unexpected deploy-
ment of airbags and unnecessary maintenance, fol-
low the instructions in this manual when performing
maintenance on airbag components or nearby, and
airbag wiring harnesses or nearby.
To prevent unexpected deployment, perform the
steps below and then wait at least 20 seconds to
discharge electricity before beginning work.
 Step 1: Turn the ignition switch OFF.
 Step 2: Disconnect the ground cable from bat-
tery.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose airbag modules in the
same way as other refuse. Follow all government
regulations concerning disposal of refuse.
7. AIRBAG MODULE
Adhere to the following when handling and storing
the airbag module to prevent bodily injury from un-
expected deployment:
 Do not hold the harnesses or connectors to carry
module.
 Do not face the bag in the direction that it opens
towards yourself or other people.
 Do not face the bag in the direction that it opens
towards the floor or walls.
8. AIRBAG SPECIAL TOOLS
To prevent unexpected deployment, only use spe-
cial tools.
9. WINDOW
Always wear safety glasses when working around
any glass to prevent glass fragments from damag-
ing your eyes.
10.WINDOW ADHESIVE
Always use the recommended or alternative adhe-
sive when attaching glass to prevent it from coming
loose and falling, resulting in accidents and injury.

NT-6
NOTE
Note
8. TIE-DOWNS
Tie-downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-downs only
to the specified points on the vehicle.
(A) Front (C) Hook for tie-down (D) Rear
(B) Hook for towing and tie-down
NT-00006
(B)
(C)(B)
(A)
(D)
(C)

NT-7
NOTE
Note
 Chain direction at tie-down condition
 Chain pulling range at tie-down condition Vehicle sinking volume at tie-down condition
Measure the distance L between tire highest point
to arch highest point before tie-down and after tie-
down. Difference of measurement value (drop
height) shall be within 50 mm (1.97 in). Make sure
to fix the vehicle securely.
9. TOWING
Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD or AT use a loader
instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or ve-
hicle:
 Do not tow other vehicles with a front hook for tie-down.
 Make sure the vehicle towing is heavier that the vehicle being towed.
(A) Chain pulling range at tie-down condition
NT-00007
NT-00008
: (A)
NT-00082
L
L