2001 forester service manual quick reference index body section
Contents
1. 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 gt 7 Remove rear quarter lower trim E C A D CON QU Hook pawl S5M0412B 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 rear quarter upper trim be sure to set rear mole as shown in the figure Outside gt Inside Mole Weatherstrip B5M0673A EI 39 SUN VISOR Exterior Interior Trim 18 Sun Visor A REMOVAL S911359A18 Remove mounting screws then detach sun visor A and hook B S5M0454A B INSTALLATION Install in the reverse order of removal 40 ROOF TRIM 19 Roof Trim s A REMOVAL 5911360418 CAUTION When removing clip use great care not to dam age the roof trim 1 Disconnect ground cable from battery 2 Remove head console S5M0243 3 Remove sun visor and hook of both sides Ref to El 40 REMOVAL Sun Visor 4 Remove assist grips A B5M1025A 5 Remove upper inner trim Ref to EI B7 REMOVAL Upper Inner Trim 6 Remove rear quarter trim Ref to El h9 REMOVAL Rear quarter Trim 7 Detach sunroof g2. for 5 to 10 minutes using an infrared lamp B CAUTION Do not overheat until plastic wrap is somewhat white 5 Using a plastic spatula remove traces of two sided tape from body panel 6 Remove masking tape and clean traces of two sided tape using a cloth dampened with white gasoline 7 Similarly clean traces of adhesive from two sided tape on side protector CAUTION Make sure side protector is clean and free of adhesive remover Clean if necessary B INSTALLATION 1 Apply primer to original side protector if used and attach two sided tape A to upper of side pro tectors as shown Two sided tape Thickness 1 2 mm 0 047 in Width 5 mm 0 20 in Recommended primer SUMITOMO 3MK 500 or equivalent Recommended two sided tape SUMITOMO 3M5305 or equivalent A 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 EI 23 PROTECTOR Exterior Interior Trim 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 Ib with roller Do not allow air to enter mating surface of the two CAUTION e To maintain adhesive power do not wash the vehicle for 24 hours after tape application e Push clip in securely
3. B INSTALLATION sossen Install in the reverse order of removal EI 28 ROOF RAIL Exterior Interior Trim 12 Roof Rail A REMOVAL 5911383418 1 Remove roof trim Ref to El441 REMOVAL Roof Trim 2 Remove seven mounting nuts and then detach roof rail carefully Section A S5M0171A B INSTALLATION zi 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 5911382 INSTALLATION S911382A11 A REMOVAL ss Install in the reverse order of removal 1 Remove shift knob and drive select lever MT model 2 Remove console cover A and front cover B o A H c A 2 B 007 3 Remove console box S5M0043 EI 30 INSTRUMENT PANEL ASSEMBLY 14 Instrument Panel Assembly 5911381 REMOVAL 5911381418 Airbag system wiring harness is routed near com bination meter CAUTION e All airbag system wiring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuits e Be careful not to damage airbag system wir ing harness when servicing the instrument panel NOTE The following positions for removal and installation are for LHD models The positions for RHD mod els are symmetrically opposite 1 Disconnect GND cable from battery 2 Rem
4. Metallic paint Hardener PB Thinner T 306 e Mixing ratio Main agent vs hardener 10 1 e Viscosity 10 13 sec 20 C 68 F e Film thickness 15 201 e Spraying pressure 245 343 kPa 2 5 3 5 kg cm 36 50 psi Not required Dry at normal temperature 10 min or more at 20 C 68 F In half dried condition avoid dust dirt Top coat paint II Not required Apply a clear coat to parts with top coat paint 1 three times at 5 7 minutes intervals e Paint in use Metallic paint Hardener PB Thinner T 301 e Mixing ratio Clear vs hardener 6 1 e Viscosity 14 16 sec 20 C 68 F e Film thickness 25 30u e Spraying pressure 245 343 kPa 2 5 3 5 kg cm 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 Inspection Paint check Masking removal Remove masking in process No 2 El 14 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 lus tre 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 unde
5. using hands To prevent deformation do not use excessive force 24 COWL PANEL 8 Cowl Panel 5911387 REMOVAL 5911387418 1 Remove cowl panel side A S5M0167 2 Open hood 3 Remove wiper arm lt Ref to WW 14 REMOVAL Wiper Arm gt 4 Lift cowl panel RH and then lift cowl panel LH Clip Cowl panel RH S5M0168A B INSTALLATION Install in the reverse order of removal EI 25 Exterior Interior Trim FRONT DOOR TRIM Exterior Interior Trim 9 Front Door Trim gt gt A REMOVAL 5911356418 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 A I LL B INSTALLATION Install in the reverse order of removal ELT S5M0450A 26 REAR DOOR TRIM 10 Rear Door Trim sn A REMOVAL 5911354418 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 Install in the reverse order of removal EI 27 Exterior Interior Trim GLOVE BOX Exterior Interior Trim 11 Glove Box gt A REMOVAL S911558A18 Loosen screws to remove glove box 55 0047
6. 1384A18 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 G D AD fr A iy C B p Hook pawl Ka S5M0452A 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 center pillar upper trim and front pillar upper trim be sure to set front mole as shown in figure Outside Qd smum Inside Mole Weatherstrip B5M0673A 37 LOWER INNER TRIM Exterior Interior Trim 16 Lower Inner Trim se A REMOVAL 5911369 18 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 D Th wor Hook pawl 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 Exterior Interior Trim 17 Rear Quarter Trim s A REMOVAL S911358A18 1 Remove rear rail trim A
7. 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM HEATER VENTILATOR AND A C AIRBAG SYSTEM SEAT BELT SYSTEM LIGHTING SYSTEM 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 reassem bling inspection and adjustment of com ponents 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 genu ine parts WIPER AND WASHER SYSTEMS ENTERTAINMENT COMMUNICATION SYSTEM GLASS WINDOWS MIRRORS BODY STRUCTURE INSTRUMENTATION DRIVER INFO IDI SEATS SE SECURITY AND LOCKS SL SUNROOF T TOP CONVERTIBLE TOP SR SUNROOF EXTERIOR INTERIOR TRIM EXTERIOR BODY PANELS CRUISE CONTROL SYSTEM CC All information illustration and specifica tions contained in this manual are based on the latest product information avail able at the time of publication approval FUJI HEAVY INDUSTRIES LTD G8050GE6 EXTERIOR INTERIOR TRIM EI NO 0 DD NN k sch AS HS HS sch sch D NO M A ONTO Page General Descriptio
8. 7 Del RE UE 10 Front Under Cover 11 POUR 42 Hear BUMP el 19 OA EN 21 Protector oo pd COW Patel mI DOR metn eH cL 25 Front Door TIM ettet IR ete cnr repe Ec AREE ub 26 Rear Door TIS p7 Roof Ball 29 Console BOX EE 30 Instrument Panel Assembly 31 Upper Inner Tim mc S 37 Lower lt ex Rear Quarter Tim en sententia atrose eas 39 SUN WEE 40 Roof TM EE Rear Gate Tim 42 Elan E EE 43 Bile Te Eet m deet eneen 44 Exterior Interior Trim GENERAL DESCRIPTION 1 General Description sv A COMPONENT 8911001 05 1 FRONT BUMPER S911001A0501 S5M0500A 1 Bumper face 2 Spacer 3 E Afoam 4 Back beam b Beam upper 6 Plate 7 Bracket Tightening torque N m kgf m ft Ib T1 33 3 4 25 T2 70 7 1 51 EL GENERAL DESCRIPTION Exterior Interior Trim 2 REAR BUMPER S911001A0511 S5M0392A Lower bracket Side upper bracket Bumper face Bumper side plate Bumper beam Cushion Lower center bracket Rear bumper plate Tightening torque N m kgf m ft Ib T 93 9 5 69 A A A A D TT A A A A O1 5 TE EL GENERAL DESCRIPTION Exterior Interior Trim 3 SIDE PROTECTOR S911001A0504 S5M0393A 1 Side pro
9. PER Exterior Interior Trim 4 Front Bumper sn A REMOVAL 5911371418 CAUTION e Handle bumper carefully to avoid damage to bumper face e Do not damage body during removal or installation of bumper e 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 gt 4 Remove headlight washer nozzle Headlight washer equipped vehicle Ref to WW 24 REMOVAL Headlight Washer 5 Remove the extension of both sides S5M0152A 6 Remove the seven clips and then detach plate A S5M0397A 7 Remove under cover lt Ref to EI 11l 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 por tion and then remove bolt S5M0154 10 Remove bumper face and E A foam 11 Remove the four bolts and then detach the back beam S5M0398 El 12 FRONT BUMPER Exterior Interior Trim 12 Remove the four bolts and then detach the beam upper S5M0156 B INSTALLATION Install in the reverse order of removal CAUTION e Handle bumper carefully to avoid dama
10. arnish A Sunroof equipped model L A S5M0305B 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 B5M0675A 9 Remove clips and then remove roof trim 55 0413 INSTALLATION S911360A11 Install in the reverse order of removal 41 REAR GATE TRIM Exterior Interior Trim 20 Rear Gate Trim gt A REMOVAL 5911357418 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 Install in the reverse order of removal 42 FLOOR MAT Exterior Interior Trim 21 Floor Mat gt A REMOVAL 5911362418 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 80 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 r
11. ear heater duct 9 Roll mat and then take it out of opened rear door 55 0240 B INSTALLATION Install in the reverse order of removal NOTE e Secure mat firmly with hook and Velcro tape e Insert mat edge firmly into the groove of side sill COVer 43 LUGGAGE FLOOR MAT Exterior Interior Trim 22 Luggage Floor Mat s A REMOVAL S911353A18 Remove clips then detach rear floor mats and boxes A P E BEN p E 55 0241 B INSTALLATION Install in the reverse order of removal EL AA
12. ge to bumper face e Do not damage body during removal or installation of bumper 13 Exterior Interior Trim FRONT BUMPER REPAIR 8911371 19 1 COATING METHOD FOR PP BUMPER sso Process Process name No Job contents Bumper mounting Masking Degreasing cleaning Set bumper on paint worktable if required Use paint worktable conforming to inner shape of bumper when possible Bumper Set bumper section G5M0164 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 Primer paint Apply primer one to all parts to be painted using air gun Use primer clear Drying 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 Top coat paint I Solid color Metallic color Use section block paint for top coat e Paint in use for each color Solid paint Hardener PB Thinner T 301 e Mixing ratio Main agent vs hardener 4 1 e Viscosity 10 13 sec 20 C 68 F e Film thickness 35 45u e Spraying pressure 245 343 kPa 2 5 3 5 kg cm 36 50 psi Use section block paint for top coat e Paint in use for each color
13. ide using a PP welding rod and heater gun Welded spot Use heater gun and PP welding rod PP base surface section NOTE e Do not melt welding rod until it flows out This results in reduced strength e Leave the welded spot unattended until it cools completely G5M0166 16 Process Process name No FRONT BUMPER Exterior Interior Trim Job contents Welding Using a heater gun and PP welding rod weld the beveled spot while melting the rod and dam aged area Welding rod Welding rod Melt hatched Section area G5M0167 NOTE e Melt the sections indicated by hatched area e Do not melt welding rod until it flows out in order to provide strength e Always keep the heater gun 1 to 2 cm 0 4 to 0 8 in away from the welding spot e Leave the welded spot unattended until it cools completely Sanding II Masking 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 OT Ty G5M0168 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 Cleaning degreasing Completely clean the entire coated area using solvent similar to that used in Process No 4 Primer c
14. le 2 Remove screws and clips Move mud guard toward the center of the body and remove mud guard S5M0166 B INSTALLATION Insert hook into body and tighten it with screw and clip EI 21 Exterior Interior Trim PROTECTOR Exterior Interior Trim 7 Protector sn A REMOVAL 5911380 18 5 Of 6 amp S5M0400A 1 Side protector Door 4 Side protector Rear quarter 7 Clip 2 Side protector Side sill b Screw 3 Side protector Front fender 6 Clip EI 22 PROTECTOR Exterior Interior Trim 1 Attach masking tape A on the upper painted area of the protector _ S5M0501A 2 Release clip engagement using clip remover and remove the protector while peeling off two sided tape S5M0502 NOTE e To increase adhesive remover strength leave two sided tape on body and side protector e f two sided tape is too thick use a putty knife to cut it thin so that adhesive remover is ready for use e f two sided tape is hard to remove heat to approximately 40 C 104 F 3 Apply an even coat of adhesive remover to the two sided tape Recommended adhesive remover SUMITOMO 3M4000 or equivalent CAUTION Do not apply adhesive remover to lacquer base coated body panels 4 Attach plastic wrap A to adhesive remover coated areas and heat to 40 to 60 C 104 to 140 F
15. le 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 Job contents Bumper removal Remove bumper as required Part removal Remove parts built into bumper as required Bumper placement Bumper Place bumper on a paint worktable as required It is recommended that contour of worktable accommodate internal shape of bumper Set bumper section G5M0164 Surface preparation Cutting 6 Sanding Cleaning Remove dust oil etc from areas to be repaired and surrounding areas using a suitable sol vent NRM No 900 Precleno white gasoline or alcohol Unit mm in 20 30 0 79 1 18 Paint surface If nature of damage are cracks or holes cut a vA 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 PP base surface G5M0165 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 Temporary welding Grind the side just opposite the beveled area with sand paper 40 to 60 and clean using a solvent Temporarily spot weld the s
16. ll parts on bumper in reverse order of removal Bumper installation Install bumper Top coat 1 Top coat Il Not required El 18 REAR BUMPER 5 Rear Bumper s A REMOVAL 5911370418 CAUTION e Handle bumper carefully to avoid damage to bumper face e Do not damage body during removal or installation of bumper e 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 2 7 1 O i 5 Lit 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 8 Remove rear bumper beam 19 Exterior Interior Trim REAR BUMPER Exterior Interior Trim B INSTALLATION s CAUTION e Handle bumper carefully to avoid damage to bumper face e Do not damage body during removal or installation of bumper Install in the reverse order of removal C REPAIR 8911370 19 Refer to front bumper repair Ref to EI 12l REMOVAL Front Bumper 20 MUD GUARD 6 Mud Guard s A REMOVAL 5911374418 1 Jack up the vehic
17. necessary for easy reassembly LHD model Disconnect connector 18P White 24P Blue 16P White Airbag connector Yellow S5M0378A EI 33 INSTRUMENT PANEL ASSEMBLY Exterior Interior Trim RHD model Remove bolt or nut Disconnect connector 18P White 32P White 14P Black Airbag connector Yellow S5M0379A EI 34 INSTRUMENT PANEL ASSEMBLY Exterior Interior Trim 15 Remove front defroster grille and two bolts S5M0051 16 Remove instrument panel carefully from the body CAUTION e Do not pull the harness when disconnecting the connector e Take care not to scratch the instrument panel and related parts e When storing removed instrument panel with passenger airbag module place it standing up on the floor G5M0602 EI 35 INSTRUMENT PANEL ASSEMBLY Exterior Interior Trim B INSTALLATION Install in the reverse order of removal CAUTION e Be careful not to snag the harness e Make sure to connect harness connector e 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 A S5M0052A EI 36 UPPER INNER TRIM Exterior Interior Trim 15 Upper Inner Trim sns A REMOVAL S91
18. oating 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 cm 36 to 50 psi with a spray gun Leave unattended 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 Primer surfacer coating Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 minutes Recommended surfacer e UPS 300 Flex Primer e No 303 UPS 300 Exclusive hardener e NPS 725 Exclusive Reducer thinner e Mixing ratio 2 1 UPS 300 No 303 e Viscosity 12 14 sec 20 C 68 F e Coated film thickness 40 50u Drying Allow the coated surface to dry for 60 minutes at 20 C 68 F or 30 minutes at 60 C 140 F Sanding III Sand the coated surface and its surrounding areas using 400 sand paper and water Cleaning degreasing Same as Process No 12 El 17 FRONT BUMPER Exterior Interior Trim Process No Process name Job contents Solid color Metallic color Use a block coating method Use a block coating method e Recommended paint e Recommended paint Sunc
19. ove shift knob and drive select lever MT model 3 Remove console cover A and front cover B o A H 4 Remove console box Ta B S5M0297A S5M0043 Exterior Interior Trim 5 Remove lower cover and then disconnect con nector JM lt PRESE Je A 6 Disconnect data link connector A from lower cover S5M0044A S5M0045A S5M0046 55 0047 EI 31 INSTRUMENT PANEL ASSEMBLY Exterior Interior Trim 9 Remove center panel and disconnect connec 13 Disconnect temperature control cable and tor mode control cable from heater unit then discon 10 Remove audio nect recirc control cable from intake unit NOTE Do not move switch and link when installing Recirc switch mperature control switch L Mode selector Switch S5M0048A 11 Remove two bolts and lower steering column Temperature control switch P ad Mode selector switch ot G5M0278 S5M0049A 12 Set temperature control switch to FULL HOT mode selector switch to DEF position and recirc switch to FRESH position 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
20. rstanding about the matter Repair methods are outlined below based on a classification of the extent of damage e Minor damage causing only a change in the lustre of the bumper due to a light touch Almost restorable Process No Process name Job contents 1 Cleaning Clean the area to be repaired using water Sanding 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 Recom Perform either the same operation as for the mended wax NITTO KASEI Soft 99 TIRE resin section or process No 18 and subse WAX BLACK or equivalent quent operations in the 3 section depend Polish the waxed area with a clean cloth after ing on the degree and nature of damage 5 to 10 minutes e Deep damage caused by scratching fences etc A dent cannot be repaired but a whitened or swelled part can be removed Process Process name Job contents Cleaning Clean damaged area with water Remova okaam Cut off protruding area if any due to collision using a putty knife aged area Sanding Grind the affected area with 100 to 500 sand paper Resin section Coated section Finish Perform Process No 12 and subsequent Same as Process No 3 in the 1 section operations in the 3 section 15 Exterior Interior Trim FRONT BUMPER e Deep damage such as a break or ho
21. ryl SC Suncryl SC No 307 Flex Hardener No 307 Flex Hardener SC Reducer thinner SC Reducer thinner e Mixing ratio 3 1 e Mixing ratio 3 1 Suncryl SC vs No 307 Flex Hardener Suncryl SC vs No 307 Flex Hardener e Viscosity 11 13 sec 20 C 68 F e Viscosity 11 13 sec 20 C 68 F e Coated film thickness 40 50u e Coated film thickness 20 30u e Spraying thickness 245 343 kPa e Spraying thickness 245 343 kPa 2 5 3 5 kg cm 36 50 psi 2 5 3 5 kg cm 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 e Recommended paint SC710 Overlay Clear No 307 Flex Hardener SC Reducer thinner e Mixing ratio 3 1 Suncryl SC vs No 307 Flex Hardener e Viscosity 10 13 sec 20 C 68 F e Coated film thickness 20 30u e Spraying pressure 245 343 kPa 2 5 3 5 kg cm 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 Insta
22. tector Front fender 3 Side protector Rear door 5 Side protector Side sill 2 Side protector Front door 4 Side protector Rear quarter El 4 GENERAL DESCRIPTION Exterior Interior Trim 4 DOOR TRIM S911001A0505 REAR GATE N S5M0448A 1 Gusset cover b Handle 9 Side trim 2 Weatherstrip 6 Pocket 10 Lower trim 3 Trim panel 7 Speaker grille 4 Pull handle 8 Upper trim EI 5 GENERAL DESCRIPTION Exterior Interior Trim 5 INNER TRIM S911001A0512 13 S5M0406A 1 Front pillar upper trim 6 Rear quarter lower trim 11 Center pillar lower trim 2 Center pillar upper trim 7 Rear skirt trim 12 Side sill rear lower cover 3 Rear pillar upper trim 8 Front pillar lower trim 13 Side sill front upper cover 4 Cover 9 Center pillar cover 14 Side sill front lower cover b Pocket 10 Side sill rear upper cover EI 6 6 INSTRUMENT PANEL GENERAL DESCRIPTION Exterior Interior Trim Pad amp 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 2 Pocket 3 Panel center 4 Center pocket lid 5 Grille center 6 Cup holder 7 Side pocket 8 Lower cover ASSY 9 Meter visor 0 Grille vent D 1 Console cover 2 Console lid EI 7 S5M0377A 23 Rear cup holder 24 Console bo
23. x 25 Console pocket 26 Rear console BRKT 27 Front cover Tightening torque N m kgf m ft Ib T 7 0 7 5 1 GENERAL DESCRIPTION Exterior Interior Trim T INNER ACCESSORIES 591100140510 3 5 S5M0449A 1 Hook 3 Assist rail bracket 5 Assist grip fixed 2 Sun visor 4 Assist grip retractable EI 8 GENERAL DESCRIPTION Exterior Interior Trim B PREPARATION TOOL TOOL NAME REMARKS Clip remover Used for removal of trim Adhesive remover Used for removal of side protector Primer Used for installation of side protector Infrared lamp Used for disassembly assembly of side protector Tow sided tape Used for installation of side protector EI 9 FRONT GRILLE Exterior Interior Trim 2 Front Grille gt A REMOVAL 5911379418 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 C stopder B INSTALLATION soon 1 Attach all clips to front grille 2 Align them with clip holes in body and push them into place S5M0401A 10 FRONT UNDER COVER Exterior Interior Trim 3 Front Under Cover s A REMOVAL 5911372418 1 Lift up the vehicle 2 Loosen bolts and clips to remove under cover S5M0402 B INSTALLATION Install in the reverse order of removal El 11 FRONT BUM
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