service SUBARU FORESTER 1999 Service Owner's Guide

Process
No.Process name Job contents
9 WeldingUsing a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam-
aged area.
G5M0167
NOTE:
IMelt the sections indicated by hatched area.
IDo not melt welding rod until it flows out, in order to provide strength.
IAlways keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
ILeave the welded spot unattended until it cools completely.
10 Sanding (II)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.
G5M0168
Sand the welded spot smooth with #240 sand paper.
11 MaskingMask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12Cleaning/
degreasingCompletely clean the entire coated area, using solvent similar to that used in Process No. 4.
13 Primer coatingApply 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
2, 36 to 50 psi) with a spray gun.
14 Leave unattended.Leave the repaired area unattended at 20ÉC (68ÉF) for 10 to 15 minutes until primer is half-dry.
NOTE:
If dirt or dust gets on the coated area, wipe it off with a cloth dampended with alcohol. (Do not
use thinner since the coated area tends to melt.)
15Primer surfacer
coatingApply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5
minutes.
Recommended surfacer:
IUPS 300 Flex Primer
INo. 303 UPS 300 Exclusive hardener
INPS 725 Exclusive Reducer (thinner)
IMixing ratio:2:1(UPS 300: No. 303)
IViscosity: 12 Ð 14 sec/20ÉC (68ÉF)
ICoated film thickness: 40 Ð 50
16 Drying Allow the coated surface to dry for 60 minutes at 20ÉC (68ÉF) [or 30 minutes at 60ÉC (140ÉF)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
18Cleaning/
degreasingSame as Process No. 12.
36
5-1[W6C0]SERVICE PROCEDURE
6. Repair Instructions for Colored PP Bumper

Process
No.Process name Job contents
19 Top coat (I)Solid color Metallic color
Use a ªblockº coating method.
IRecommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
IMixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex Hardener
IViscosity: 11 Ð 13 sec/20ÉC (68ÉF)
ICoated film thickness: 40 Ð 50
ISpraying thickness: 245 Ð 343 kPa
(2.5 Ð 3.5 kg/cm
2, 36 Ð 50 psi)Use a ªblockº coating method.
IRecommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
IMixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex Hardener
IViscosity: 11 Ð 13 sec/20ÉC (68ÉF)
ICoated film thickness: 20 Ð 30
ISpraying thickness: 245 Ð 343 kPa
(2.5 Ð 3.5 kg/cm2, 36 Ð 50 psi)
20 Leave unattended. Not required.Leave unattended at 20ÉC (68ÉF) for at least
10 minutes until the topcoated area is half-dry.
NOTE:
Be careful to keep dust or dirt from getting on
the affected area.
21 Top coat (II) Not required.Apply a clear coat three times at an interval of
3 to 5 minutes.
IRecommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
IMixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex Hardener
IViscosity: 10 Ð 13 sec/20ÉC (68ÉF)
ICoated film thickness: 20 Ð 30
ISpraying pressure: 245 Ð 343 kPa
(2.5 Ð 3.5 kg/cm
2, 36 Ð 50 psi)
22 DryingAllow the coated surface to dry at 20ÉC (68ÉF) for two hours or 60ÉC (140ÉF) for 30 minutes.
NOTE:
Do not allow the temperature to exceed 80ÉC (176ÉF) since this will deform the PP substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
26Bumper installa-
tionInstall bumper.
37
[W6C0]5-1SERVICE PROCEDURE
6. Repair Instructions for Colored PP Bumper

15. Sunroof
A: REMOVAL AND INSTALLATION
1. GLASS LID
1) Completely close glass lid and open sunshade.
2) Detach the four covers (A) and then remove
eight nuts.
S5M0292A
3) Carefully remove glass lid.
4) Install in the reverse order of removal.
2. SUNROOF FRAME
1) Remove roof trim.
2) Remove glass lid.
3) Disconnect the four drain tubes (A) from sun-
roof frame.
4) Disconnect sunroof harness connector.
5) Remove installation bolts and nuts and then
detach sunroof frame.
S5M0293A
6) Install in the reverse order of removal.
CAUTION:
Be careful not to snag the harness.
NOTE:
IMake sure to connect harness connector.IWhen installing drain tube, insert it securely into
drain pipe.
Length A:
15 mm (0.59 in) or more
G5M0205
B: ADJUSTMENT
1. ALIGNMENT OF HEIGHT BETWEEN
SUNROOF GLASS LID AND ROOF PANEL
Loosen sunroof glass lid installation nuts and then
adjust height by adding (max: two pieces) and
extracting (max: one piece) shim(s) (A) (standard:
one piece) between sunroof glass lid (B) and roof
panel (C).
Difference in height between sunroof glass lid
and roof panel:
0
±1.0 mm (0±0.039 in)
S5M0294B
42
5-1[W15A1]SERVICE PROCEDURE
15. Sunroof

2. CHECKING FOR MOVEMENT OF
SUNROOF PANEL ITSELF
1) Place a cloth on sunshade, and attach a spring
scale to sunshade edge using the cloth.
S5M0295
2) Pull spring scale to measure force required to
move sunshade.
Force required to move sunshade:
Less than 24.5
±4.9 N (2.5±0.5 kg, 5.5±1.1
lb)
NOTE:
Considerable effort is required to start sunshade
moving, so take scale reading while sunroof panel
is moving smoothly.
3) If force required exceeds specifications, check
the sunroof glass lid, sunshade and deflector, and
guide rail assembly for improper installation.
16. Crossbar
A: REMOVAL
1) Loosen and remove TORX bolt T30 from the
top of each crossbar end support, and then remove
inner clamp.
S5M0330A
(1) TORX bolt T30
(2) End support
(3) Inner clamp
(4) Roof rail
2) Remove crossbar.
NOTE:
When removing the front crossbar from the roof
rail, first move the front crossbar to the center of
the roof rail.
B: INSTALLATION
1. FRONT CROSSBAR
NOTE:
Front crossbar has ªMAXIMUM LOAD ROOF
RACK-150LBS. EVENLY DISTRIBUTED ROOF
SURFACE-100LBS. EVENLY DISTRIBUTEDº
label on LH side.
1) Loosen and remove TORX bolt T30 from the
top of each crossbar end support, and then remove
the inner clamp.
43
[W16B1]5-1SERVICE PROCEDURE
16. Crossbar

1. Door Alignment
S5M0380A
2
5-2[S100]SPECIFICATIONS AND SERVICE DATA
1. Door Alignment

2. Door
A: REMOVAL AND INSTALLATION
1. DOOR ASSEMBLY
1) Remove front pillar lower trim [W5A1].> and disconnect connectors from body
harness.
B5M0726
2) Place a cloth or a wood block under door to
prevent damage, and support it with a jack.
3) Remove checker bolt.
Tightening torque:
32
±10 N´m (3.3±1.0 kg-m, 23.9±7.2 ft-lb)
S5M0183
4) Remove bolts (M8) securing upper and lower
hinges to door, and remove door from hinges.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
5) Remove hinges by loosening hinges mounting
bolt (M8) off of body.
Tightening torque:
29
±5 N´m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
CAUTION:
Work carefully to avoid damaging door.
G5M0385
6) Install in the reverse order of removal.
NOTE:
Apply grease to moving parts of door hinges.
14
5-2[W2A1]SERVICE PROCEDURE
2. Door

2. TRIM PANEL
CAUTION:
Be careful not to break clip by applying undue
force.
1) Front door trim:
(1) Remove gusset cover (A), power window
switch assembly (B) and pocket (C).
(2) Remove screws and then disengage the
clips.
(3) Detach trim panel and then disconnect con-
nector.
(4) Install in the reverse order of removal.
2) Rear door trim:
(1) Remove handle (E), pocket (F) and clips
(G).
(2) Remove screws and then disengage the
clips.
(3) Detach trim panel and then disconnect con-
nector.
(4) Install in the reverse order of removal.
S5M0383A
3. SEALING COVER
1) Remove trim panel.
2) Remove speaker, trim bracket, remote assem-
bly and disconnect connectors.
3) Remove sealer with a spatula.
CAUTION:
Be careful because cover may break if sealer is
removed forcefully.
G5M0391
4) Install in the reverse order of removal.
NOTE:
IConfirm that sealer is properly applied without
breaks. Then install sealing cover.
IWhen repairing or replacing sealing cover, use
ªCEMEDINE 5430Lº as sealer. It may be overlaid
on existing sealer.
Sealer:
CEMEDINE 5430L
CAUTION:
IAny breaks in sealer can cause water leak-
age or entry of air and dust. Be sure sealer is
applied in a continuous line.
IMake sure sealing cover bonded areas are
free from wrinkles or openings.
15
[W2A3]5-2SERVICE PROCEDURE
2. Door

4. CHECKER
1) Completely close door glass.
2) Remove trim panel.
3) Remove sealing cover.
4) Remove attaching bolt to body.
5) Loosen two nuts securing checker, and take out
checker through access hole in underside.
S5M0363A
6) Install in the reverse order of removal.
Tightening torque:
T1: 7.5
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4
ft-lb)
T2: 32
±10 N´m (3.3±1.0 kg-m, 23.9±7.2
ft-lb)
5. INNER REMOTE
1) Remove trim panel.
2) Remove sealing cover.
3) Disconnect joints of two rods.
4) Unlatch rod holder.
5) Remove inner remote assembly.
S5M0186
6) Install in the reverse order of removal.
NOTE:
If rear door is equipped with child safety lock,
check that child lock lever moves without dragging.
6. DOOR LATCH AND OUTER HANDLE
1) Completely close door glass.
2) Remove door trim panel.
3) Remove inner remote assembly.
4) Remove sealing cover around latch service
hole.
5) Remove latch and actuator assembly (A):
(1) Turn rod holder to disconnect joint between
key lock and rod.
(2) Turn rod holder to disconnect joint between
outer handle and rod.
(3) Turn rod holder to disconnect joint between
crank and rod.
(4) Loosen screws securing both latch and
actuator, then remove latch and actuator
assembly through service hole in bottom.
S5M0189A
(5) Install in the reverse order of removal.
Tightening torque (screw):
6.4
±2.0 N´m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
NOTE:
ICheck operation of each part.
ICheck each sliding part for proper lubrication.
CAUTION:
After installation, be sure lock mechanism
operates normally.
16
5-2[W2A4]SERVICE PROCEDURE
2. Door

6) Remove outer handle (B):
(1) Remove trim panel.
(2) Remove sealing cover.
(3) Loosen bolts securing outer handle and
then remove outer handle from outside.
CAUTION:
Be careful not to damage door.
S5M0189A
(4) Install in the reverse order of removal.
Tightening torque:
7.4
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
7. KEY LOCK
1) Remove trim panel.
2) Remove sealing cover.
3) Completely close door glass.
4) Remove outer handle.
5) Loosen spring securing key lock.
6) Remove key lock from outer handle.
7) Install in the reverse order of removal.
8. GUSSET
1) Be sure window is all the way down.
2) Remove gusset cover.
3) Remove trim panel.
4) Remove door rearview mirror.
5) Remove outer weatherstrip.
6) Remove sealing cover.
NOTE:
Be careful not to drop nuts inside the door.7) Remove bolts and nuts which secure gusset.
Tightening torque: Bolt
13
±3 N´m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
Tightening torque: Nut
7.4
±2.0 N´m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
S5M0190
8) Lift out gusset.
9) Install in the reverse order of removal.
B: ADJUSTMENT
1. DOOR ASSEMBLY
1) Using ST, loosen bolts securing upper and
lower hinges to body, and adjust fore-and-aft and
vertical alignment of door.
ST 925610000 DOOR HINGE WRENCH
B5M0933A
2) Loosen screw one complete rotation, and
adjust opening/closing direction of door using a
hammer covered with a cloth.
CAUTION:
Be careful not to damage striker.
Hinge tightening torque (body side):
29
±5 N´m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
Striker tightening torque:
18
±4 N´m (1.8±0.4 kg-m, 13.0±2.9 ft-lb)
17
[W2B1]5-2SERVICE PROCEDURE
2. Door

2. INNER REMOTE
1) Lock the door.
2) Loosen bolt (A).
3) Lower bell crank (B) and then tighten bolt (A).
S5M0191A
3. PROCEDURE CHART FOR ADJUSTING DOOR GLASS
H5M0912B
18
5-2[W2B2]SERVICE PROCEDURE
2. Door