2001 forester service manual quick reference index body section

2001 forester service manual quick reference index body section
2001 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.
G8050GE6
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.
Page
General Description.....................................................................................2
Front Grille.................................................................................................10
Front Under Cover.....................................................................................11
Front Bumper ............................................................................................12
Rear Bumper .............................................................................................19
Mud Guard ................................................................................................21
Protector ....................................................................................................22
Cowl Panel ................................................................................................25
Front Door Trim .........................................................................................26
Rear Door Trim..........................................................................................27
Glove Box..................................................................................................28
Roof Rail....................................................................................................29
Console Box ..............................................................................................30
Instrument Panel Assembly.......................................................................31
Upper Inner Trim .......................................................................................37
Lower Inner Trim .......................................................................................38
Rear Quarter Trim .....................................................................................39
Sun Visor...................................................................................................40
Roof Trim...................................................................................................41
Rear Gate Trim..........................................................................................42
Floor Mat ...................................................................................................43
Luggage Floor Mat ....................................................................................44
GENERAL DESCRIPTION
Exterior/Interior Trim
1. General Description
A: COMPONENT
S911001A05
1. FRONT BUMPER
S911001A0501
S911001
S5M0500A
(1)
(2)
(3)
(4)
Bumper face
Spacer
E/A foam
Back beam
(5) Beam upper
(6) Plate
(7) Bracket
EI-2
Tightening torque: N·m (kgf-m, ft-lb)
T1: 33 (3.4, 25)
T2: 70 (7.1, 51)
GENERAL DESCRIPTION
2. REAR BUMPER
Exterior/Interior Trim
S911001A0511
S5M0392A
(1)
(2)
(3)
(4)
Bumper beam
Cushion
Lower center bracket
Rear bumper plate
(5)
(6)
(7)
(8)
Lower bracket
Side upper bracket
Bumper face
Bumper side plate
EI-3
Tightening torque: N·m (kgf-m, ft-lb)
T: 93 (9.5, 69)
GENERAL DESCRIPTION
Exterior/Interior Trim
3. SIDE PROTECTOR
S911001A0504
S5M0393A
(1) Side protector (Front fender)
(2) Side protector (Front door)
(3) Side protector (Rear door)
(4) Side protector (Rear quarter)
EI-4
(5) Side protector (Side sill)
GENERAL DESCRIPTION
4. DOOR TRIM
Exterior/Interior Trim
S911001A0505
S5M0448A
(1)
(2)
(3)
(4)
Gusset cover
Weatherstrip
Trim panel
Pull handle
(5)
(6)
(7)
(8)
Handle
Pocket
Speaker grille
Upper trim
EI-5
(9) Side trim
(10) Lower trim
GENERAL DESCRIPTION
Exterior/Interior Trim
5. INNER TRIM
S911001A0512
S5M0406A
(1)
(2)
(3)
(4)
(5)
Front pillar upper trim
Center pillar upper trim
Rear pillar upper trim
Cover
Pocket
(6)
(7)
(8)
(9)
(10)
Rear quarter lower trim
Rear skirt trim
Front pillar lower trim
Center pillar cover
Side sill rear upper cover
EI-6
(11)
(12)
(13)
(14)
Center pillar lower trim
Side sill rear lower cover
Side sill front upper cover
Side sill front lower cover
GENERAL DESCRIPTION
6. INSTRUMENT PANEL
Exterior/Interior Trim
S911001A0508
S5M0377A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Pad & frame
Grille side (D)
Front def. grille
Grille side (P)
Grille vent (P)
Glove box panel
Glove box lid
Knob
Instrument panel center console
BRKT (Radio)
Center console cover
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Pocket
Panel center
Center pocket lid
Grille center
Cup holder
Side pocket
Lower cover ASSY
Meter visor
Grille vent (D)
Console cover
Console lid
EI-7
(23)
(24)
(25)
(26)
(27)
Rear cup holder
Console box
Console pocket
Rear console BRKT
Front cover
Tightening torque: N·m (kgf-m, ft-lb)
T: 7 (0.7, 5.1)
Exterior/Interior Trim
7. INNER ACCESSORIES
GENERAL DESCRIPTION
S911001A0510
S5M0449A
(1) Hook
(2) Sun visor
(3) Assist rail bracket
(4) Assist grip (retractable)
EI-8
(5) Assist grip (fixed)
GENERAL DESCRIPTION
B: PREPARATION TOOL
S911001A17
TOOL NAME
Clip remover
Adhesive remover
Primer
Infrared lamp
Tow-sided tape
Exterior/Interior Trim
Used
Used
Used
Used
Used
EI-9
for
for
for
for
for
REMARKS
removal of trim.
removal of side protector.
installation of side protector.
disassembly/assembly of side protector.
installation of side protector.
FRONT GRILLE
Exterior/Interior Trim
2. Front Grille
A: REMOVAL
S911379
S911379A18
1) Open hood.
2) Remove the four upper clips from the body
panel. Push the part shown in the figure by using
a screwdriver while lightly pulling the front grille.
S5M0401A
B: INSTALLATION
S911379A11
1) Attach all clips to front grille.
2) Align them with clip holes in body and push
them into place.
EI-10
FRONT UNDER COVER
3. Front Under Cover
A: REMOVAL
S911372
S911372A18
1) Lift-up the vehicle.
2) Loosen bolts and clips to remove under cover.
S5M0402
B: INSTALLATION
S911372A11
Install in the reverse order of removal.
EI-11
Exterior/Interior Trim
FRONT BUMPER
Exterior/Interior Trim
4. Front Bumper
A: REMOVAL
S911371
S911371A18
CAUTION:
쐌 Handle bumper carefully to avoid damage to
bumper face.
쐌 Do not damage body during removal or
installation of bumper.
쐌 To avoid damage to bumper, lay removed
bumper on sheet spread on the floor. Do not lay
it directly on the floor.
1) Disconnect the ground cable from the battery.
2) Remove front fog light. <Ref. to LI-48,
REMOVAL, Front Fog Light Assembly.>
3) Remove the front grille. <Ref. to EI-10,
REMOVAL, Front Grille.>
4) Remove headlight washer nozzle. (Headlight
washer equipped vehicle) <Ref. to WW-24,
REMOVAL, Headlight Washer.>
5) Remove the extension of both sides.
7) Remove under cover. <Ref. to EI-11,
REMOVAL, Front Under Cover.>
8) Remove the seven clips from under side of
bumper.
S5M0153
9) Turn over the front mud guard of the front portion and then remove bolt.
S5M0154
10) Remove bumper face and E/A foam.
11) Remove the four bolts and then detach the
back beam.
S5M0152A
6) Remove the seven clips and then detach plate
(A).
S5M0398
S5M0397A
EI-12
FRONT BUMPER
12) Remove the four bolts and then detach the
beam upper.
S5M0156
B: INSTALLATION
S911371A11
Install in the reverse order of removal.
CAUTION:
쐌 Handle bumper carefully to avoid damage to
bumper face.
쐌 Do not damage body during removal or
installation of bumper.
EI-13
Exterior/Interior Trim
Exterior/Interior Trim
C: REPAIR
FRONT BUMPER
S911371A19
1. COATING METHOD FOR PP BUMPER
Process
No.
Process name
1
Bumper mounting
S911371A1901
Job contents
Set bumper on paint worktable if required. Use
paint worktable conforming to inner shape of
bumper when possible.
G5M0164
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
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.
쐌 Paint in use (for each color):
쐌 Paint in use (for each color):
Metallic paint
Solid paint
Hardener PB
Hardener PB
Thinner T-306
Thinner T-301
쐌 Mixing ratio:
쐌 Mixing ratio:
Main agent vs. hardener = 10:1
Main agent vs. hardener = 4:1
쐌 Viscosity: 10 — 13 sec/20°C (68°F)
쐌 Viscosity: 10 — 13 sec/20°C (68°F)
쐌 Film thickness: 15 — 20µ
쐌 Film thickness: 35 — 45µ
쐌 Spraying pressure: 245 — 343 kPa
쐌 Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
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.
쐌 Paint in use:
Metallic paint
Hardener PB
Thinner T-301
Not required.
쐌 Mixing ratio: Clear vs. hardener = 6:1
쐌 Viscosity: 14 — 16 sec/20°C (68°F)
쐌 Film thickness: 25 — 30µ
쐌 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 masking in process No. 2.
EI-14
FRONT BUMPER
Exterior/Interior Trim
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER
S911371A1902
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.
쐌 Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
Process
Process name
No.
1
Cleaning
2
Sanding
3
Finish
Job contents
Clean the area to be repaired using water.
Grind the repairing area with #500 sand paper
Resin section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recommended wax: NITTO KASEI Soft 99 TIRE
WAX BLACK, or equivalent.
Polish the waxed area with a clean cloth after
5 to 10 minutes.
in a “feathering” motion.
Coated section
Perform either the same operation as for the
resin section or process No. 18 and subsequent operations in the “(3)” section, depending on the degree and nature of damage.
쐌 Deep damage caused by scratching fences, etc.
A dent cannot be repaired but a whitened or swelled part can be removed.
Process
Process name
No.
1
Cleaning
Removal of dam2
aged area
3
Sanding
4
Finish
Job contents
Clean 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
Same as Process No. 3 in the “(1)” section.
operations in the “(3)” section.
EI-15
Exterior/Interior Trim
FRONT BUMPER
쐌 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
Process name
No.
1
Bumper removal
2
Part removal
Job contents
Remove bumper as required.
Remove parts built into bumper as required.
Place bumper on a paint worktable as
required.
It is recommended that contour of worktable
accommodate internal shape of bumper.
3
Bumper placement
4
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solSurface preparation
vent (NRM No. 900 Precleno, white gasoline, or alcohol).
G5M0164
5
Cutting
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 “veeout” the affected area using a knife or grinder.
G5M0165
6
7
Sanding (I)
Cleaning
8
Temporary welding
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.
G5M0166
NOTE:
쐌 Do not melt welding rod until it flows out. This results in reduced strength.
쐌 Leave the welded spot unattended until it cools completely.
EI-16
FRONT BUMPER
Process
No.
Process name
Exterior/Interior Trim
Job contents
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged area.
9
Welding
G5M0167
NOTE:
쐌 Melt the sections indicated by hatched area.
쐌 Do not melt welding rod until it flows out, in order to provide strength.
쐌 Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
쐌 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)
G5M0168
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 halfdry.
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:
쐌 UPS 300 Flex Primer
쐌 No. 303 UPS 300 Exclusive hardener
쐌 NPS 725 Exclusive Reducer (thinner)
쐌 Mixing ratio: 2 : 1 (UPS 300: No. 303)
쐌 Viscosity: 12 — 14 sec/20°C (68°F)
쐌 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-17
Exterior/Interior Trim
Process
No.
19
20
21
22
23
24
25
26
FRONT BUMPER
Process name
Job contents
Solid color
Use a “block” coating method.
쐌 Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
쐌 Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
쐌 Viscosity: 11 — 13 sec/20°C (68°F)
쐌 Coated film thickness: 40 — 50µ
쐌 Spraying thickness: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Metallic color
Use a “block” coating method.
쐌 Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
Top coat (I)
쐌 Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
쐌 Viscosity: 11 — 13 sec/20°C (68°F)
쐌 Coated film thickness: 20 — 30µ
쐌 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.
Leave unattended. 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.
쐌 Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
Top coat (II)
Not required.
쐌 Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
쐌 Viscosity: 10 — 13 sec/20°C (68°F)
쐌 Coated film thickness: 20 — 30µ
쐌 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.
Drying
NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP substrate.
Inspection
Carefully check the condition of the repaired area.
Masking removal
Remove masking tape applied in Process No. 11 and 13.
Parts installation
Install parts on bumper in reverse order of removal.
Bumper installation Install bumper.
EI-18
REAR BUMPER
5. Rear Bumper
A: REMOVAL
Exterior/Interior Trim
8) Remove rear bumper beam.
S911370
S911370A18
CAUTION:
쐌 Handle bumper carefully to avoid damage to
bumper face.
쐌 Do not damage body during removal or
installation of bumper.
쐌 To avoid damage to bumper, lay removed
bumper on sheet spread on the floor. Do not lay
it directly on the floor.
1) Disconnect the ground cable from the battery.
2) Open rear gate.
3) Remove the five screws and the clip from the
rear bumper.
S5M0399
4) Disconnect license plate light and rear fog light
(if equipped) connectors.
5) Remove bolts and clips from under side of
bumper.
S5M0157
6) Remove bumper face.
7) Remove bolts from bumper stay.
G5M0161
EI-19
REAR BUMPER
Exterior/Interior Trim
B: INSTALLATION
S911370A11
CAUTION:
쐌 Handle bumper carefully to avoid damage to
bumper face.
쐌 Do not damage body during removal or
installation of bumper.
Install in the reverse order of removal.
C: REPAIR
S911370A19
Refer to front bumper repair. <Ref. to EI-12
REMOVAL, Front Bumper.>
EI-20
MUD GUARD
6. Mud Guard
A: REMOVAL
S911374
S911374A18
1) Jack-up the vehicle.
2) Remove screws and clips. Move mud guard
toward the center of the body and remove mud
guard.
S5M0166
B: INSTALLATION
S911374A11
Insert hook into body, and tighten it with screw and
clip.
EI-21
Exterior/Interior Trim
PROTECTOR
Exterior/Interior Trim
7. Protector
S911380
A: REMOVAL
S911380A18
S5M0400A
(1) Side protector (Door)
(2) Side protector (Side sill)
(3) Side protector (Front fender)
(4) Side protector (Rear quarter)
(5) Screw
(6) Clip
EI-22
(7) Clip
PROTECTOR
1) Attach masking tape (A) on the upper painted
area of the protector.
Exterior/Interior Trim
4) Attach plastic wrap (A) to adhesive remover
coated areas and heat to 40 to 60°C (104 to 140°F)
for 5 to 10 minutes using an infrared lamp (B).
CAUTION:
Do not overheat until plastic wrap is somewhat
white.
S5M0501A
2) Release clip engagement using clip remover,
and remove the protector while peeling off twosided tape.
S5M0503A
5) Using a plastic spatula, remove traces of twosided tape from body panel.
6) Remove masking tape and clean traces of twosided tape using a cloth dampened with white
gasoline.
7) Similarly, clean traces of adhesive from twosided tape on side protector.
CAUTION:
Make sure side protector is clean and free of
adhesive remover. Clean if necessary.
S5M0502
NOTE:
쐌 To increase adhesive remover strength, leave
two-sided tape on body and side protector.
쐌 If two-sided tape is too thick, use a putty knife to
cut it thin so that adhesive remover is ready for
use.
쐌 If two-sided tape is hard to remove, heat to
approximately 40°C (104°F).
B: INSTALLATION
3) Apply an even coat of adhesive remover to the
two-sided tape.
Recommended primer:
SUMITOMO 3MK-500 or equivalent
Recommended adhesive remover:
SUMITOMO 3M4000 or equivalent
Recommended two-sided tape:
SUMITOMO 3M5305 or equivalent
S911380A11
1) Apply primer to original side protector (if used),
and attach two-sided tape (A) to upper of side protectors as shown.
Two-sided tape:
Thickness; 1.2 mm (0.047 in)
Width; 5 mm (0.20 in)
CAUTION:
Do not apply adhesive remover to lacquer base
coated body panels.
S5M0504A
2) Using an infrared lamp, heat body panel to 40
to 60°C (104 to 140°F) and rear surface of side
protector to 20 to 30°C (68 to 86°F).
EI-23
Exterior/Interior Trim
PROTECTOR
3) Remove tack paper from two-sided paper.
While aligning clips with holes in body panel,
attach two-sided tape to side protector and body
panel with a force of more than 49 N (5 kg, 11 lb)
with roller. Do not allow air to enter mating surface
of the two.
CAUTION:
쐌 To maintain adhesive power, do not wash the
vehicle for 24 hours after tape application.
쐌 Push clip in securely using hands.
(To prevent deformation, do not use excessive
force.)
EI-24
COWL PANEL
8. Cowl Panel
A: REMOVAL
S911387
S911387A18
1) Remove cowl panel side.
S5M0167
2) Open hood.
3) Remove wiper arm. <Ref. to WW-14
REMOVAL, Wiper Arm.>
4) Lift cowl panel (RH), and then lift cowl panel
(LH).
S5M0168A
B: INSTALLATION
S911387A11
Install in the reverse order of removal.
EI-25
Exterior/Interior Trim
FRONT DOOR TRIM
Exterior/Interior Trim
9. Front Door Trim
A: REMOVAL
S911356
S911356A18
CAUTION:
Do not apply excessive force to clip. Otherwise
the clip may be broken.
1) Remove gusset cover (A), power window
switch assembly (B) and pocket (C).
2) Remove screws, and then detach trim panel.
S5M0450A
B: INSTALLATION
S911356A11
Install in the reverse order of removal.
EI-26
REAR DOOR TRIM
10. Rear Door Trim
A: REMOVAL
S911354
S911354A18
CAUTION:
Do not apply excessive force to clip. Otherwise
the clip may be broken.
1) Remove handle (A), pocket (B) and clips (C).
2) Remove screws, and then detach trim panel.
S5M0451A
B: INSTALLATION
S911354A11
Install in the reverse order of removal.
EI-27
Exterior/Interior Trim
GLOVE BOX
Exterior/Interior Trim
11. Glove Box
A: REMOVAL
S911558
S911558A18
Loosen screws to remove glove box.
S5M0047A
B: INSTALLATION
S911558A11
Install in the reverse order of removal.
EI-28
ROOF RAIL
12. Roof Rail
A: REMOVAL
Exterior/Interior Trim
S911383
S911383A18
1) Remove roof trim. <Ref. to EI-41 REMOVAL, Roof Trim.>
2) Remove seven mounting nuts and then detach roof rail carefully.
S5M0171A
B: INSTALLATION
S911383A11
Install in the reverse order of removal.
CAUTION:
Be careful not to scratch body panels with roof
rail stud bolts when removing and installing
them.
EI-29
CONSOLE BOX
Exterior/Interior Trim
13. Console Box
A: REMOVAL
B: INSTALLATION
S911382
S911382A11
Install in the reverse order of removal.
S911382A18
1) Remove shift knob and drive select lever (MT
model).
2) Remove console cover (A) and front cover (B).
S5M0297A
3) Remove console box.
S5M0043
EI-30
INSTRUMENT PANEL ASSEMBLY
14. Instrument Panel Assembly
S911381
A: REMOVAL
Exterior/Interior Trim
5) Remove lower cover and then disconnect connector.
S911381A18
Airbag system wiring harness is routed near combination meter.
CAUTION:
쐌 All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.
쐌 Be careful not to damage airbag system wiring harness when servicing the instrument
panel.
NOTE:
The following positions for removal and installation
are for LHD models. The positions for RHD models are symmetrically opposite.
S5M0044A
6) Disconnect data link connector (A) from lower
cover.
1) Disconnect GND cable from battery.
2) Remove shift knob and drive select lever. (MT
model)
3) Remove console cover (A) and front cover (B).
S5M0045A
7) Remove knee panel.
S5M0297A
4) Remove console box.
S5M0046
8) Remove glove box.
S5M0043
S5M0047A
EI-31
Exterior/Interior Trim
INSTRUMENT PANEL ASSEMBLY
9) Remove center panel and disconnect connector.
10) Remove audio.
13) Disconnect temperature control cable and
mode control cable from heater unit then disconnect recirc control cable from intake unit.
NOTE:
Do not move switch and link when installing.
S5M0048A
11) Remove two bolts and lower steering column.
G5M0278
S5M0049A
12) Set temperature control switch to “FULL
HOT”, mode selector switch to “DEF” position and
recirc switch to “FRESH” position.
EI-32
INSTRUMENT PANEL ASSEMBLY
Exterior/Interior Trim
14) Disconnect harness connectors and then remove the installing bolts and nuts.
CAUTION:
Be sure to hold socket section and not harness when disconnecting.
NOTE:
Put matching mark, if necessary, for easy reassembly.
S5M0378A
EI-33
Exterior/Interior Trim
INSTRUMENT PANEL ASSEMBLY
S5M0379A
EI-34
INSTRUMENT PANEL ASSEMBLY
15) Remove front defroster grille and two bolts.
S5M0051
16) Remove instrument panel carefully from the
body.
CAUTION:
쐌 Do not pull the harness when disconnecting
the connector.
쐌 Take care not to scratch the instrument panel
and related parts.
쐌 When storing removed instrument panel with
passenger airbag module, place it standing up
on the floor.
G5M0602
EI-35
Exterior/Interior Trim
Exterior/Interior Trim
B: INSTALLATION
INSTRUMENT PANEL ASSEMBLY
S911381A11
Install in the reverse order of removal.
CAUTION:
쐌 Be careful not to snag the harness.
쐌 Make sure to connect harness connector.
쐌 Take care not to scratch the instrument panel
and related parts.
NOTE:
When setting the instrument panel into position,
push the two pins into grommet on the body panel.
S5M0052A
EI-36
UPPER INNER TRIM
15. Upper Inner Trim
A: REMOVAL
S911384
S911384A18
1) Remove front mole (A).
2) Remove front pillar upper trim (B).
3) Remove center pillar cover (C).
4) Detach front seat belt shoulder anchor.
5) Loosen screws to remove center pillar upper
trim (D).
S5M0452A
B: INSTALLATION
S911384A11
Install in the reverse order of removal.
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing center pillar upper trim and front
pillar upper trim, be sure to set front mole as shown
in figure.
B5M0673A
EI-37
Exterior/Interior Trim
LOWER INNER TRIM
Exterior/Interior Trim
16. Lower Inner Trim
A: REMOVAL
S911369
S911369A18
1) Remove front pillar lower trim (A).
2) Remove side sill front upper cover (B).
3) Remove rear seat cushion <Ref. to SE-6
REMOVAL, Rear Seat.>, then remove side sill rear
upper cover (C).
4) Remove center pillar cover (D).
5) Remove front seat belt shoulder anchor.
6) Loosen screws to remove center pillar upper
trim (E).
7) Remove center pillar lower trim (F).
S5M0453A
B: INSTALLATION
S911369A11
Install in the reverse order of removal.
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
EI-38
REAR QUARTER TRIM
17. Rear Quarter Trim
A: REMOVAL
B: INSTALLATION
S911358
Exterior/Interior Trim
S911358A11
Install in the reverse order of removal.
S911358A18
1) Remove rear rail trim (A).
2) Remove strut cover (B).
3) Remove rear seat belt anchor.
4) Remove caps and screws, and then remove
rear quarter upper trim (C).
5) Remove rear skirt trim (D).
6) Remove luggage floor mat. <Ref. to EI-44,
REMOVAL, Luggage Floor Mat.>
7) Remove rear quarter lower trim (E).
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing rear quarter upper trim, be sure to
set rear mole as shown in the figure.
B5M0673A
S5M0412B
EI-39
SUN VISOR
Exterior/Interior Trim
18. Sun Visor
A: REMOVAL
S911359
S911359A18
Remove mounting screws then detach sun visor
(A) and hook (B).
S5M0454A
B: INSTALLATION
S911359A11
Install in the reverse order of removal.
EI-40
ROOF TRIM
19. Roof Trim
A: REMOVAL
Exterior/Interior Trim
8) Remove cover (B) while detaching snap lock
carefully. Put the rear seat belt tongue (A) out to
the other side of the trim through the hole.
S911360
S911360A18
CAUTION:
When removing clip, use great care not to damage the roof trim.
1) Disconnect ground cable from battery.
2) Remove head console.
B5M0675A
9) Remove clips and then remove roof trim.
S5M0243
3) Remove sun visor and hook of both sides.
<Ref. to EI-40, REMOVAL, Sun Visor.>
4) Remove assist grips (A).
S5M0413
B: INSTALLATION
S911360A11
Install in the reverse order of removal.
B5M1025A
5) Remove upper inner trim. <Ref. to EI-37,
REMOVAL, Upper Inner Trim.>
6) Remove rear quarter trim. <Ref. to EI-39,
REMOVAL, Rear quarter Trim.>
7) Detach sunroof garnish (A). (Sunroof equipped
model)
S5M0305B
EI-41
REAR GATE TRIM
Exterior/Interior Trim
20. Rear Gate Trim
A: REMOVAL
S911357
S911357A18
CAUTION:
Be careful not to damage clips or their holes.
Remove rear gate inner handle (A) from rear gate
and then detach trim panel.
S5M0386A
B: INSTALLATION
S911357A11
Install in the reverse order of removal.
EI-42
FLOOR MAT
21. Floor Mat
A: REMOVAL
S911362
S911362A18
1) Remove front seats. <Ref. to SE-5 REMOVAL,
Front Seat.>
2) Remove rear seat cushion. <Ref. to SE-6
REMOVAL, Rear Seat.>
3) Remove console box. <Ref. to EI-30 Console
Box.>
4) Remove front pillar lower trim, side sill rear
upper cover and center pillar lower trim. <Ref. to
EI-38 REMOVAL, Lower Inner Trim.>
5) Remove clips from floor mat.
NOTE:
When pulling out edge, do not pull mat alone; pull
mat together with edge. Ply off two steel clips on
side sill front cover and one on side sill rear cover
using screwdriver.
6) Remove mat hook.
7) Remove mat from toe board area.
8) Remove mat from rear heater duct.
9) Roll mat, and then take it out of opened rear
door.
S5M0240
B: INSTALLATION
S911362A11
Install in the reverse order of removal.
NOTE:
쐌 Secure mat firmly with hook and Velcro tape.
쐌 Insert mat edge firmly into the groove of side sill
cover.
EI-43
Exterior/Interior Trim
LUGGAGE FLOOR MAT
Exterior/Interior Trim
22. Luggage Floor Mat
A: REMOVAL
S911353
S911353A18
Remove clips, then detach rear floor mats and
boxes.
S5M0241
B: INSTALLATION
S911353A11
Install in the reverse order of removal.
EI-44
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