2004 forester service manual quick reference index body section

2004 forester service manual quick reference index body section
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, reassembling, inspection and adjustment of
components and diagnostics for guidance 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 specifications contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
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
G8080GE7
2004 FORESTER SERVICE MANUAL
QUICK REFERENCE INDEX
BODY SECTION
CRUISE CONTROL SYSTEM
CC
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4SO)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4DOTC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4DOTC 2.5)
IMMOBILIZER (DIAGNOSTIC)
IM
G8080GE7
EXTERIOR/INTERIOR TRIM
EI
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Page
General Description ....................................................................................2
Front Grille ................................................................................................18
Hood Grille ................................................................................................19
Front Under Cover ....................................................................................22
Front Bumper ............................................................................................23
Rear Bumper.............................................................................................30
Mud Guard ................................................................................................31
Cowl Panel ................................................................................................32
Side Sill Spoiler .........................................................................................33
Side Garnish .............................................................................................34
Front Door Trim .........................................................................................35
Rear Door Trim .........................................................................................36
Glove Box..................................................................................................37
Roof Rail ...................................................................................................38
Console Box..............................................................................................39
Instrument Panel Assembly ......................................................................40
Upper Inner Trim .......................................................................................43
Lower Inner Trim .......................................................................................44
Rear Quarter Trim .....................................................................................45
Sun Visor...................................................................................................46
Roof Trim ..................................................................................................47
Rear Gate Trim .........................................................................................48
Floor Mat ...................................................................................................49
Luggage Floor Mat ....................................................................................50
Instrument Panel Center Compartment ....................................................51
Heat Shield Cover .....................................................................................52
General Description
EXTERIOR/INTERIOR TRIM
1. General Description
A: COMPONENT
1. FRONT GRILLE
(3)
(4)
(1)
(2)
EI-00230
(1)
(2)
Front grille
Front grille emblem
(3)
Clip
(4)
Hook
2. UNDER COVER
(1)
T
(3)
(4)
T
(3)
(2)
(3)
(1)
(2)
Under cover
Service hole cover
(3)
(4)
Clip
Bolt
EI-00002
Tightening torque: N·m (kgf-m, ft-lb)
T: 18 (1.84, 13.3)
EI-2
General Description
EXTERIOR/INTERIOR TRIM
3. HOOD GRILLE
(8)
(6)
(1)
(2)
(3)
(7)
(9)
(10)
(5)
(3)
(4)
T
EI-00003
(1)
(2)
(3)
(4)
(5)
Hood grille
Black clip
Black clip
Packing B
Bolt
(6)
(7)
(8)
(9)
(10)
Grille duct
Clip
Packing C
Packing A
Duct bellows
Tightening torque: N·m (kgf-m, ft-lb)
T: 4.4 (0.45, 3.25)
4. HEAT SHIELD COVER
(3)
(2)
(1)
EI-00089
(1)
Front heat shield cover
(2)
Center heat shield cover
EI-3
(3)
Rear heat shield cover
General Description
EXTERIOR/INTERIOR TRIM
5. FRONT BUMPER
T2
T2
(6)
(5)
(4)
T1
(7)
(9)
(8)
(2)
(9)
(10)
(3)
T1
(9)
(9)
(1)
EI-00751
(1)
(2)
(3)
(4)
(5)
Bumper face
E/A form
Fog light
Side bracket
Main beam
(6)
(7)
(8)
(9)
(10)
Upper beam
Lower beam
Lower beam reinforcement
Clip
Slider side front
EI-4
Tightening torque: N·m (kgf-m, ft-lb)
T1: 32 (3.3, 24)
T2: 69 (7.0, 51)
General Description
EXTERIOR/INTERIOR TRIM
6. REAR BUMPER
(2)
(5)
T2
(4)
(7)
T1
T1
(6)
(8)
T5
T4
T3
T3
(3)
(1)
EI-00005
(1)
(2)
(3)
(4)
(5)
(6)
Bumper face
Rear bumper upper beam
Rear arch cover
Rear bumper front side bracket
Center bracket
Stay COMPL
(7)
(8)
Rear bumper side bracket ASSY
Rear bumper upper beam side
EI-5
Tightening torque: N·m (kgf-m, ft-lb)
T1: 32 (3.3, 24)
T2: 7.4 (0.75, 5.46)
T3: 4.4 (0.45, 3.26)
T4: 93 (9.5, 68.7)
T5: 1.8 (0.18, 1.3)
General Description
EXTERIOR/INTERIOR TRIM
7. MUD GUARD
(3)
(1)
(4)
(5)
(2)
(2)
(2)
EI-00238
(1)
(2)
Mud guard
Clip
(3)
(4)
Screw
Clip (S-shape)
EI-6
(5)
Air flap
General Description
EXTERIOR/INTERIOR TRIM
8. COWL PANEL
(2)
(1)
(3)
(2)
EI-00724
(1)
Cowl panel
(2)
Cowl side panel
EI-7
(3)
Seal
General Description
EXTERIOR/INTERIOR TRIM
9. SIDE SILL SPOILER
(4)
(3)
(5)
(2)
(1)
EI-00009
(1)
(2)
Side garnish (Front fender)
Side garnish (Front door)
(3)
(4)
Side garnish (Rear door)
Side garnish (Rear quarter)
EI-8
(5)
Side garnish (Side sill)
General Description
EXTERIOR/INTERIOR TRIM
10.ROOF RAIL
(1)
T
EI-00010
(1)
Roof rail
Tightening torque: N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.53)
11.DOOR TRIM
(5)
(3)
(1)
(5)
(3)
(2)
(6)
(6)
(2)
(4)
(4)
(A)
(7)
(B)
EI-00233
(A)
Front door trim
(B)
Rear door trim
(1)
(2)
(3)
Gusset cover
Bracket
Weather strip upper
(4)
(5)
(6)
Clip
Trim panel
Power window switch cover
EI-9
(7)
Ash tray
General Description
EXTERIOR/INTERIOR TRIM
12.REAR GATE TRIM
EI-00012
EI-10
General Description
EXTERIOR/INTERIOR TRIM
13.CONSOLE BOX
(4)
(3)
(2)
(1)
(5)
(7)
(6)
EI-00225
(1)
(2)
(3)
Rear cup holder
Console lid
Console cover
(4)
(5)
(6)
Console front cover
Console box
Console pocket
EI-11
(7)
Accessory socket
General Description
EXTERIOR/INTERIOR TRIM
14.INSTRUMENT PANEL
• LHD MODEL
(12)
(14)
(2)
(3)
(4)
(6)
(15)
A
(1)
(16)
(8)
(5)
(7)
A
(9)
(13)
(10)
(11)
EI-00793
(1)
(2)
(3)
(4)
(5)
(6)
Pad & frame
Center compartment
Grille cover
Lower cover
Coin box
Meter visor
(7)
(8)
(9)
(10)
(11)
(12)
Center panel
Air vent grille
Cup holder
Glove box panel
Glove box lid
Steering beam
EI-12
(13)
(14)
(15)
(16)
Grille cover
Air vent grille (Defroster)
Switch panel
Passenger’s airbag module
General Description
EXTERIOR/INTERIOR TRIM
• RHD MODEL
(12)
(14)
(2)
(3)
(6)
A
(15) (4)
(1)
(16)
(8)
(5)
(7)
A
(13)
(9)
(10)
(11)
EI-00226
(1)
(2)
(3)
(4)
(5)
(6)
Pad & frame
Center compartment
Grille cover
Lower cover
Coin box
Meter cover
(7)
(8)
(9)
(10)
(11)
(12)
Center panel
Air vent grille
Cup holder
Glove box panel
Glove box lid
Steering beam
EI-13
(13)
(14)
(15)
(16)
Grille cover
Air vent grille (Defroster)
Switch panel
Passenger’s airbag module
General Description
EXTERIOR/INTERIOR TRIM
15.INNER TRIM
(3)
T
(2)
(14)
(16)
(15)
(7)
(5)
(6)
(1)
T
(13)
(10)
(12)
(9)
(11)
(8)
(4)
EI-00015
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Front pillar upper trim
Center pillar upper trim
Rear pillar upper trim
Rear rail trim
Insulator
Rear quarter lower trim
Strut cap
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Rear skirt trim
Side sill rear cover
Center pillar lower trim
Side sill front cover
Front garnish
Rear garnish
Front pillar inner rib
EI-14
(15)
(16)
Center pillar inner rib
Bracket
Tightening torque: N·m (kgf-m, ft-lb)
T: 2 (0.20, 1.46)
General Description
EXTERIOR/INTERIOR TRIM
16.ROOF TRIM
EI-00016
17.FLOOR MAT
(A)
(1)
EI-00111
(A)
Vehicle front
(1)
Floor mat
EI-15
General Description
EXTERIOR/INTERIOR TRIM
18.LUGGAGE FLOOR MAT
(4)
(3)
(2)
(5)
(1)
EI-00220
(1)
(2)
Front floor mat
Floor box
(3)
(4)
Side floor mat RH
Center floor mat
EI-16
(5)
Side floor mat LH
General Description
EXTERIOR/INTERIOR TRIM
19.INNER ACCESSORIES
(1)
T
T
T
(2)
(3)
T
T
EI-00229
(1)
(2)
Hook
Sun visor
(3)
Assist grip (Retractable)
Tightening torque: N·m (kgf-m, ft-lb)
T: 2 (0.20, 1.46)
B: PREPARATION TOOL
TOOL NAME
Clip remover
Clip clamp pliers
REMARKS
Used for removal of trim.
Used for removal of various clips and clamps.
EI-17
Front Grille
EXTERIOR/INTERIOR TRIM
2. Front Grille
B: INSTALLATION
A: REMOVAL
1) Remove the three hooks remained on body during removal, then install them to front grille.
1) Open the front hood.
2) Remove the two upper clips of front grille side.
Slide the front grille side to vehicle outside, then remove the four lower hooks (A) to remove front grille
side.
EI-00021
: (A)
NOTE:
Make sure that the clip direction is correct.
2) Install the front grille to body.
3) Install the front grille side.
EI-00019
(A) Hook
3) Remove the four upper clips (A) of front grille,
then pull the front grille up and remove the three
hooks (B) to remove front grille.
: (A)
: (B)
EI-00020
(A) Clip
(B) Hook
EI-18
Hood Grille
EXTERIOR/INTERIOR TRIM
3. Hood Grille
A: REMOVAL
1) Remove the five screws and clip (A) to remove
hood duct.
(A)
EI-00022
2) Remove the five nuts.
EI-00023
3) Remove the three black clips to remove hood
grille.
EI-00024
EI-19
Hood Grille
EXTERIOR/INTERIOR TRIM
B: INSTALLATION
(A)
(B)
(2)
(3)
(1)
(B)
(C)
(A)
Black clip
(B)
Black clip
1) Replace the black clip (1), (2) with a new one. Install the clip with arrow mark facing the front side of
grille (A).
EI-00025
(C)
Bolt
4) Install the five nuts.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.25 ft-lb)
(A)
EI-00026
2) Replace the black clip (3) with a new one.
3) Insert the hood grille clip and engage the three
clips.
EI-00028
5) Catch the two hooks (A) of hood duct to the hood
holes.
NOTE:
Make sure that the anchor portion of each clip is
firmly engaged.
(A)
EI-00029
EI-00027
EI-20
Hood Grille
EXTERIOR/INTERIOR TRIM
6) Install the hood duct with clip (A) and five screws.
(A)
EI-00022
C: INSPECTION
Make sure that the clip is firmly engaged.
Make sure that there is no abnormal gap at whole
periphery of hood grille.
Make sure that there is no damage on hood grille.
EI-21
Front Under Cover
EXTERIOR/INTERIOR TRIM
4. Front Under Cover
A: REMOVAL
1) Lift-up the vehicle.
2) Loosen the bolts, remove the clips, and then remove the under cover.
EI-00030
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
18 N·m (1.84 kgf-m, 13.3 ft-lb)
EI-22
Front Bumper
EXTERIOR/INTERIOR TRIM
5. Front Bumper
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Loosen the two clips to remove the mud guard and
front under cover.
5) Remove the front grille and front grille side.
<Ref. to EI-18, REMOVAL, Front Grille.>
6) Remove the eight clips, and pull out the bumper
slightly.
EI-00034
EI-00031
3) Turn over the mud guard, and remove two inside
clips which securing front bumper to fender.
7) Remove the E/A FORM from bumper beam.
E/A FORM may easily break. Do not apply excessive force to it during removal.
EI-00035
8) Remove the bumper beam.
EI-00036
EI-00032
4) Turn over the mud guard, and disconnect the fog
light connector before removing a bolt and clip
which installed to under side of fog light hole.
9) Remove the eight bolts to disassemble the front
bumper beam.
EI-00095
EI-00033
EI-23
Front Bumper
EXTERIOR/INTERIOR TRIM
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Description.
<Ref. to EI-4, FRONT BUMPER, COMPONENT, General Description.>
EI-24
Front Bumper
EXTERIOR/INTERIOR TRIM
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Process
No.
Process name
Job contents
(1)
1
Bumper mounting
Set the bumper on paint worktable if required.
Use paint worktable conforming to inner shape
of bumper when possible.
(2)
2
Masking
4
Degreasing, cleaning
Primer paint
5
Drying
6
Top coat paint (I)
7
Drying
8
Top coat paint (II)
9
Drying
10
11
Inspection
Masking removal
3
EI-00038
(1) Bumper
(2) Set bumper section
Mask specified part (black base) with masking tape. Use masking tape for PP (example, Nichiban
No. 533, etc.).
Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
Apply primer one to all parts to be painted, using air gun. Use primer (clear).
Dry at normal temperature [10 to 15 min. at 20°C (68°F)].
In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.
Solid color
Metallic color
Use section (block) paint for top coat.
Use section (block) paint for top coat.
• Paint in use (for each color):
• Paint in use (for each color):
Metallic paint
Solid paint
Hardener PB
Hardener PB
Thinner T-306
Thinner T-301
• Mixing ratio:
• Mixing ratio:
Main agent vs. hardener = 10:1
Main agent vs. hardener = 4:1
• Viscosity: 10 — 13 sec/20°C (68°F)
• Viscosity: 10 — 13 sec/20°C (68°F)
• Film thickness: 15 — 20µ
• Film thickness: 35 — 45µ
• Spraying pressure: 245 — 343 kPa
• Spraying pressure: 245 — 343 kPa
2, 36 — 50 psi)
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
(2.5 — 3.5 kg/cm
Dry at normal temperature [10 min. or more at
Not required.
20°C (68°F)].
In half-dried condition, avoid dust, dirt.
Apply a clear coat to parts with top coat paint
(I), three times, at 5 — 7 minutes intervals.
• Paint in use:
Metallic paint
Hardener PB
Thinner T-301
Not required.
• Mixing ratio: Clear vs. hardener = 6:1
• Viscosity: 14 — 16 sec/20°C (68°F)
• Film thickness: 25 — 30µ
• Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
60°C (140°F), 60 min. or 80°C (176°F), 30 min.
If higher than 80°C (176°F), PP may be deformed. Keep maximum temperature of 80°C (176°F).
Paint check.
Remove the masking in process No. 2.
EI-25
Front Bumper
EXTERIOR/INTERIOR TRIM
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER
NOTE:
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be restored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of
the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this point
to the customer and get an understanding about the matter. Repair methods are outlined below, based on a
classification of the extent of damage.
1) Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
Process
No.
1
2
3
Process name
Cleaning
Sanding
Finish
Job contents
Clean the area to be repaired using water.
Grind the repairing area with #500 sand paper in a “feathering” motion.
Resin section
Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). RecomPerform either the same operation as for the
mended wax: NITTO KASEI Soft 99 TIRE WAX resin section or process No. 18 and subseBLACK, or equivalent.
quent operations in the “3)” section, depending
Polish the waxed area with a clean cloth after 5 on the degree and nature of damage.
to 10 minutes.
2) Deep damage caused by scratching fences, etc.
A dent cannot be repaired but a whitened or swelled part can be removed.
Process
No.
1
Process name
3
Cleaning
Removal of damaged area
Sanding
4
Finish
2
Job contents
Clean the damaged area with water.
Cut off protruding area, if any, due to collision, using a putty knife.
Grind the affected area with #100 to #500 sand paper.
Resin section
Coated section
Perform Process No. 12 and subsequent operSame as Process No. 3 in the “1)” section.
ations in the “3)” section.
EI-26
Front Bumper
EXTERIOR/INTERIOR TRIM
3) Deep damage such as a break or hole that requires filling
Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really
worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
Process
No.
1
2
Process name
Bumper removal
Part removal
Job contents
Remove the bumper as required.
Remove the parts built into bumper as required.
(1)
3
Bumper placement
Place the bumper on a paint worktable as
required.
It is recommended that contour of worktable
accommodate internal shape of bumper.
(2)
4
Surface preparation
EI-00038
(1) Bumper
(2) Set bumper section
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol).
(3)
(1)
5
6
7
Cutting
Sanding (I)
Cleaning
If nature of damage are cracks or holes, cut a
guide slit of 20 to 30 mm (0.79 to 1.18 in) in
length along the crack or hole up to the
bumper’s base surface. Then, bevel or “vee-out”
the affected area using a knife or grinder.
(4)
(2)
EI-00235
(1) Paint surface
(2) PP base surface
(3) 20 — 30 mm (0.79 — 1.18 in)
(4) 3 mm (0.12 in)
Grind beveled surface with sand paper (#40 to #60) to smooth finish.
Clean the sanded surface with the same solvent as used in Process No. 4.
Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a solvent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.
(1)
8
Temporary welding
(2)
(3)
(1) Welded spot (Use heater gun and PP welding rod)
(2) PP base surface
(3) Beveled section
NOTE:
• Do not melt the welding rod until it flows out. This results in reduced strength.
• Leave the welded spot unattended until it cools completely.
EI-27
EI-00236
Front Bumper
EXTERIOR/INTERIOR TRIM
Process
No.
Process name
Job contents
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged area.
(2)
(2)
9
Welding
(3)
(1)
EI-00237
(1) Melt hatched area
(2) Welding rod
(3) Section
NOTE:
• Melt the sections indicated by hatched area.
• Do not melt the welding rod until it flows out, in order to provide strength.
• Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
• Leave the welded spot unattended until it cools completely.
Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife,
operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will
cause the PP substrate to melt from the heat.
10
Sanding (II)
EI-00042
11
Masking
12
Cleaning/
degreasing
13
Primer coating
14
Leave unattended.
15
Primer surfacer
coating
16
17
18
Drying
Sanding (III)
Cleaning/
degreasing
Sand the welded spot smooth with #240 sand paper.
Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
Completely clean the entire coated area, using solvent similar to that used in Process No. 4.
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if necessary.
Recommended primer: Mp/ 364 PP Primer
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa
(2.5 to 3.5 kg/cm2, 36 to 50 psi) with a spray gun.
Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with alcohol.
(Do not use thinner since the coated area tends to melt.)
Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 minutes.
Recommended surfacer:
• UPS 300 Flex Primer
• No. 303 UPS 300 Exclusive hardener
• NPS 725 Exclusive Reducer (thinner)
• Mixing ratio: 2: 1 (UPS 300: No. 303)
• Viscosity: 12 — 14 sec/20°C (68°F)
• Coated film thickness: 40 — 50µ
Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
Sand the coated surface and its surrounding areas using #400 sand paper and water.
Same as Process No. 12.
EI-28
Front Bumper
EXTERIOR/INTERIOR TRIM
Process
No.
Process name
19
Top coat (I)
20
Leave unattended.
21
Top coat (II)
22
Drying
23
24
25
26
Inspection
Masking removal
Parts installation
Bumper installation
Job contents
Solid color
Use a “block” coating method.
• Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
• Mixing ratio: 3: 1
Suncryl (SC) vs. No. 307 Flex Hardener
• Viscosity: 11 — 13 sec/20°C (68°F)
• Coated film thickness: 40 — 50µ
• Spraying thickness: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Metallic color
Use a “block” coating method.
• Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
• Mixing ratio: 3: 1
Suncryl (SC) vs. No. 307 Flex Hardener
• Viscosity: 11 — 13 sec/20°C (68°F)
• Coated film thickness: 20 — 30µ
• Spraying thickness: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Leave unattended at 20°C (68°F) for at least 10
minutes until the topcoated area is half-dry.
Not required.
NOTE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
Apply a clear coat three times at an interval of 3
to 5 minutes.
• Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
Not required.
• Mixing ratio: 3: 1
Suncryl (SC) vs. No. 307 Flex Hardener
• Viscosity: 10 — 13 sec/20°C (68°F)
• Coated film thickness: 20 — 30µ
• Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Allow the coated surface to dry at 20°C (68°F) for two hours or 60°C (140°F) for 30 minutes.
NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP substrate.
Carefully check the condition of the repaired area.
Remove the masking tape applied in Process No. 11 and 13.
Install the parts on bumper in reverse order of removal.
Install the bumper.
EI-29
Rear Bumper
EXTERIOR/INTERIOR TRIM
6. Rear Bumper
7) Remove the rear skirt trim.
8) Remove the bolt to remove bracket from
bumper.
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the bolts and clips.
EI-00047
9) Loosen the four nuts to remove rear bumper.
EI-00046
10) Disengage the clips to remove bumper upper
beam.
EI-00043
3) Remove the clips from bumper and bracket.
EI-00048
EI-00044
4) Remove the rear combination light assemblies
from each side. <Ref. to LI-21, REMOVAL, Rear
Combination Light Assembly.>
5) Remove the two clips from each side.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Description.
<Ref. to EI-5, REAR BUMPER, COMPONENT,
General Description.>
C: REPAIR
Refer to front bumper repair. <Ref. to EI-23, REMOVAL, Front Bumper.>
EI-00045
6) Remove the floor box.
EI-30
Mud Guard
EXTERIOR/INTERIOR TRIM
7. Mud Guard
A: REMOVAL
1) Jack-up the vehicle.
2) Remove the clip to remove air flap.
3) Remove the screws and clips to remove mud
guard.
EI-00049
B: INSTALLATION
Install in the reverse order of removal.
EI-31
Cowl Panel
EXTERIOR/INTERIOR TRIM
8. Cowl Panel
A: REMOVAL
1) Open the front hood.
2) Remove the wiper arm. <Ref. to WW-12, REMOVAL, Front Wiper Arm.>
3) Remove the clips to remove cowl side panels.
EI-00050
4) Loosen the clips to remove cowl panel.
: (A)
EI-0725
(A) Clip
B: INSTALLATION
Install in the reverse order of removal.
EI-32
Side Sill Spoiler
EXTERIOR/INTERIOR TRIM
9. Side Sill Spoiler
A: REMOVAL
Remove the clips (one on front fender arch, six on
bottom of side sill spoiler, one on top of side sill
spoiler), then remove the side sill spoiler.
EI-00053
B: INSTALLATION
Install in the reverse order of removal.
EI-33
Side Garnish
EXTERIOR/INTERIOR TRIM
10.Side Garnish
B: INSTALLATION
A: REMOVAL
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).
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 equivalent) to the area where double-sided tape was adhered.
NOTE:
Use 5 mm (0.2 in) width and 1 mm (0.04 in) thickness double-sided tape.
(1)
(2)
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).
EI-00109
(1)
(2)
NOTE:
When the double-sided tape is not removed completely using above steps, use the scraper.
EI-00110
(1) Double-sided tape
(2) Front side
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.
EI-34
Front Door Trim
EXTERIOR/INTERIOR TRIM
11.Front Door Trim
A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. Otherwise 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 remove upper hook. Pull down it to remove the lower
hook. Remove the inner remote cover.
EI-00054
4) Remove the power window control switch. <Ref.
to GW-7, REMOVAL, Power Window Control
Switch.>
5) Remove the clips of trim panel using clip remover to remove trim panel.
EI-00055
B: INSTALLATION
Install in the reverse order of removal.
EI-35
Rear Door Trim
EXTERIOR/INTERIOR TRIM
12.Rear Door Trim
A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. Otherwise the clip may be broken.
1) Disconnect the ground cable from battery.
2) Pull up the inner remote cover toward you to remove upper hook. Pull down it to remove the lower
hook. Remove the inner remote cover.
EI-00054
3) Remove the power window control switch. <Ref. to
GW-7, REMOVAL, Power Window Control Switch.>
4) Remove the clips of trim panel using clip remover to remove trim panel.
EI-00098
B: INSTALLATION
Install in the reverse order of removal.
EI-36
Glove Box
EXTERIOR/INTERIOR TRIM
13.Glove Box
A: REMOVAL
1) Open the glove box.
2) Loosen the screws to remove glove box.
(B)
(A)
(B)
EI-00057
(A) Hook
(B) Clip
B: INSTALLATION
Install in the reverse order of removal.
EI-37
Roof Rail
EXTERIOR/INTERIOR TRIM
14.Roof Rail
A: REMOVAL
1) Remove the roof trim. <Ref. to EI-47, REMOVAL, Roof Trim.>
2) Remove the five mounting nuts.
3) Detach the clip at front edge sideways carefully to remove the roof rail upwards.
A
A
B
A
A
C
A
B
C
a
EI-00058
NOTE:
Remove the clip at “C” area upwards while applying sideway force to deflect hook at “a” area.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be careful not to scratch the body panels with
roof rail stud bolts when removing and installing them.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.53 ft-lb)
EI-38
Console Box
EXTERIOR/INTERIOR TRIM
15.Console Box
5) Loosen the screws.
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the console front cover.
(A)
(A)
(A)
(A)
(A)
EI-00726
(A) Hook pawl
3) Remove the shift knob (MT model).
4) Loosen the screws to remove console cover.
EI-00061
6) Remove the hook pawl of console side panel to
remove console box.
(B)
(B)
(A)
(A)
EI-00060
(A) Hook pawl
(B) Clip
EI-00062
B: INSTALLATION
Install in the reverse order of removal.
EI-39
Instrument Panel Assembly
EXTERIOR/INTERIOR TRIM
16.Instrument Panel Assembly
6) Loosen the screws.
A: REMOVAL
(C)
(C)
CAUTION:
• All airbag system wiring harness and connectors are colored yellow. Do not use electrical test
equipment on these circuits.
• Be careful not to damage the airbag system
harness when servicing the instrument panel.
(B)
1. REMOVAL OF INSTRUMENT PANEL
ONLY
(A)
EI-00728
1) Disconnect the ground cable from battery.
2) Loosen the screws and clips, and then remove
the lower cover.
(A)
(A)
(A)
(A) Screw
(B) Clip
(C) Claw
7) Insert the flat tip screwdriver to the position (A)
and release the claw with pulling out the lower portion of center console panel.
(A)
CAUTION:
Do not insert the flat tip screwdriver into any
portion except for indicated in the figure.The instrument panel may be damaged.
EI-00727
(A)
(A)
(A) Clip
3) Disconnect the in-vehicle sensor hose and connector.
4) Remove the console front cover and console
cover. <Ref. to EI-39, REMOVAL, Console Box.>
5) Apply the thick protective tape (A) to instrument
panel pad to protect the surface of it.
NOTE:
Also apply the protective tape to the deep inside
portion between center console panel and instrument panel pad.
EI-00732
(A) Inserting position of flat tip screwdriver
8) Disconnect the connectors of A/C control panel
and hazard switch.
(A)
EI-00731
EI-40
Instrument Panel Assembly
EXTERIOR/INTERIOR TRIM
9) Loosen the screws and clips, and then remove
the side console panel.
NOTE:
Remove the front pillar upper trim if necessary.
<Ref. to EI-43, REMOVAL, Upper Inner Trim.>
19) Disconnect the combination meter harness connector.
CAUTION:
Do not disconnect the connector by pulling harness.
2. REMOVAL OF INSTRUMENT PANEL
WITH STEERING BEAM
1) Disconnect the ground cable from battery.
2) Loosen the screws and clips (A), and then remove
the lower cover.
EI-00103
(A)
(A)
(A)
EI-00062
10) Remove the passenger’s airbag module. <Ref.
to AB-15, REMOVAL, Passenger’s Airbag Module.>
11) Remove the two steering column installation bolts.
<Ref. to PS-26, REMOVAL, Tilt Steering Column.>
12) Loosen the four instrument panel installation
bolts. (Do not remove the lower bolts for alignment
of install location.)
EI-00727
3) Remove the console front cover and console
cover. <Ref. to EI-39, REMOVAL, Console Box.>
4) Loosen the screws and clips, and then remove
the side console panel.
EI-00103
5) Remove the steering column.
EI-00223
13) Remove the combination meter assembly. <Ref.
to IDI-10, REMOVAL, Combination Meter Assembly.>
14) Loosen the instrument panel installation screws.
15) Remove the instrument panel center compartment. <Ref. to EI-51, REMOVAL, Instrument Panel
Center Compartment.>
16) Remove the radio. <Ref. to ET-5, REMOVAL,
Radio Body.>
17) Remove the side cover of instrument panel assembly (both side), and then loosen two bolts.
18) Remove the instrument panel assembly.
EI-41
Instrument Panel Assembly
EXTERIOR/INTERIOR TRIM
6) Loosen the four instrument panel installation bolts.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
• Be careful not to snag the harness.
• Make sure to connect the harness connector.
NOTE:
When setting the instrument panel into position, push
the hook into grommet (A) on the body panel.
(A)
(A)
(A)
EI-00066
7) Remove the driver’s and passenger’s airbag module. <Ref. to AB-14, REMOVAL, Driver’s Airbag
Module.> <Ref. to AB-15, REMOVAL, Passenger’s
Airbag Module.>
8) Loosen the steering beam installation bolts.
9) Loosen the brake pedal installation bolts. <Ref.
to BR-50, REMOVAL, Brake Pedal.>
10) Remove two clips from the edge of instrument
panel assembly.
11) Remove the instrument panel assembly.
CAUTION:
Do not disconnect the connector by pulling harness.
NOTE:
• If necessary, make matching marks for easy reassembly.
• When storing the removed instrument panel, place it
standing up on the floor.
EI-00068
EI-42
EI-00069
Upper Inner Trim
EXTERIOR/INTERIOR TRIM
17.Upper Inner Trim
A: REMOVAL
1) Remove the lower inner trim. <Ref. to EI-44, REMOVAL, Lower Inner Trim.>
2) Remove the front molding (A).
3) Remove the front pillar upper trim (B).
4) Detach the front seat belt shoulder anchor, then
remove the center pillar upper trim (C).
(A)
(C)
(B)
: (D)
EI-00105
(D) Clip
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing the center pillar upper trim and front
pillar upper trim, be sure to set the front molding as
shown in the figure.
(B)
(A)
(C)
(D)
(E)
(F)
EI-00106
(A)
(B)
(C)
(D)
(E)
(F)
Outside
Inside
Molding
Weather strip
Trim
Body
EI-43
Lower Inner Trim
EXTERIOR/INTERIOR TRIM
18.Lower Inner Trim
A: REMOVAL
1) Remove the side sill front cover (A).
2) Remove the rear seat cushion <Ref. to SE-13,
REMOVAL, Rear Seat.>, then remove side sill rear
cover (B).
3) Remove the center pillar lower trim (C).
(C)
(B)
(A)
: (D)
EI-00072
(D) Clip
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
EI-44
Rear Quarter Trim
EXTERIOR/INTERIOR TRIM
19.Rear Quarter Trim
B: INSTALLATION
A: REMOVAL
Install in the reverse order of removal.
1) Remove the rear seat. <Ref. to SE-13, REMOVAL, Rear Seat.>
2) Remove the side sill rear cover.
3) Remove the rear rail trim (A).
4) Remove the strut cap.
5) Remove the shoulder anchor of rear seat belt.
6) Loosen the screws and clips to remove rear
quarter upper trim (B).
7) Remove the rear skirt trim (C).
8) Loosen the screws and clips to remove rear
quarter lower trim (D).
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing the rear quarter upper trim, be sure
to set the rear molding as shown in the figure.
(B)
(A)
(C)
(D)
(E)
(A)
(F)
EI-00106
(A)
(B)
(C)
(D)
(E)
(F)
(B)
(C)
(D)
: (E)
: (F)
EI-00073
(E) Clip
(F) Hook
EI-45
Outside
Inside
Molding
Weather strip
Trim
Body
Sun Visor
EXTERIOR/INTERIOR TRIM
20.Sun Visor
A: REMOVAL
Remove the mounting screws then detach sun visor (A) and hook (B).
(B)
(A)
EI-00074
B: INSTALLATION
Install in the reverse order of removal.
EI-46
Roof Trim
EXTERIOR/INTERIOR TRIM
21.Roof Trim
8) Remove the clips, and then remove the roof trim.
A: REMOVAL
CAUTION:
When removing the clip, use great care not to
damage the roof trim.
1) Disconnect the ground cable from battery.
2) Remove the over head console. (Sunroof model)
<Ref. to SR-9, REMOVAL, Sunroof Switch.>
3) Remove the room light. <Ref. to LI-30, REMOVAL, Room Light.>
4) Remove the sun visor and hook or both sides.
<Ref. to EI-46, REMOVAL, Sun Visor.>
5) Remove the assist grip cap to remove assist grip
(A).
EI-00077
B: INSTALLATION
Install in the reverse order of removal.
(A)
EI-00075
6) Remove the upper inner trim. <Ref. to EI-43, REMOVAL, Upper Inner Trim.>
7) Remove the rear quarter upper trim shown in the figure. <Ref. to EI-45, REMOVAL, Rear Quarter
Trim.>
(1) Remove the rear rail trim (A).
(2) Remove the rear quarter upper trim (B) of
both sides.
(A)
(B)
: (C)
EI-00076
(C) Clip
EI-47
Rear Gate Trim
EXTERIOR/INTERIOR TRIM
22.Rear Gate Trim
A: REMOVAL
CAUTION:
Be careful not to damage the clips or their holes.
Remove the rear gate inner handle (A) from rear gate
and then detach trim panel.
(A)
EI-00078
B: INSTALLATION
Install in the reverse order of removal.
EI-48
Floor Mat
EXTERIOR/INTERIOR TRIM
23.Floor Mat
A: REMOVAL
1) Remove the front seats. <Ref. to SE-6, REMOVAL, Front Seat.>
2) Remove the rear seat cushion. <Ref. to SE-13,
REMOVAL, Rear Seat.>
3) Remove the console box. <Ref. to EI-39, Console Box.>
4) Remove the side sill front cover, side sill rear
cover and center pillar lower trim. <Ref. to EI-44,
REMOVAL, Lower Inner Trim.>
5) Remove the footrest or clips from floor mat.
6) Remove the mat hook.
7) Remove the mat from toe board area.
8) Remove the mat from rear heater duct.
9) Roll the mat, and then take it out of opened rear
door.
(A)
(1)
EI-00079
(A) Vehicle front
(1) Floor mat
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
• Secure the mat firmly with hook and Velcro tape.
• Insert the mat edge firmly into the groove of side
sill cover.
EI-49
Luggage Floor Mat
EXTERIOR/INTERIOR TRIM
24.Luggage Floor Mat
A: REMOVAL
1) Remove the back mat of rear seat backrest.
2) Remove the clips, then detach the rear floor mats
and boxes.
EI-00080
B: INSTALLATION
Install in the reverse order of removal.
EI-50
Instrument Panel Center Compartment
EXTERIOR/INTERIOR TRIM
25.Instrument Panel Center
Compartment
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Insert a flat tip screwdriver, and then pry up to remove the clips.
:A
EI-00081
(A) Clip
3) Remove the instrument panel center compartment
from instrument panel.
4) Disconnect the connector from clock.
B: INSTALLATION
Install in the reverse order of removal.
EI-51
Heat Shield Cover
EXTERIOR/INTERIOR TRIM
26.Heat Shield Cover
A: REMOVAL
1. FRONT HEAT SHIELD COVER
Loosen the four bolts to remove front heat shield cover.
(A)
DI-00211
(A) Transmission mount
2. CENTER HEAT SHIELD COVER
Loosen the four bolts to remove center heat shield
cover.
EI-00107
3. REAR HEAT SHIELD COVER
1) Remove the muffler. <Ref. to EX(H4SO)-13, REMOVAL, Muffler.>
2) Loosen the four bolts to remove rear heat shield
cover.
EI-00108
B: INSTALLATION
Install in the reverse order of removal.
EI-52
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