SUBARU FORESTER 2004 Service Repair Manual

EI-25
EXTERIOR/INTERIOR TRIM
Front Bumper
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Pro-
cess
No.Process name Job contents
1 Bumper mountingSet the bumper on paint worktable if required.
Use paint worktable conforming to inner shape
of bumper when possible.
(1) Bumper
(2) Set bumper section
2MaskingMask specified part (black base) with masking tape. Use masking tape for PP (example, Nichiban
No. 533, etc.).
3Degreasing, clean-
ingClean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
5DryingDry 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.
6 Top coat paint (I)Solid color Metallic color
Use section (block) paint for top coat.
 Paint in use (for each color):
Solid paint
Hardener PB
Thinner T-301
 Mixing ratio:
Main agent vs. hardener = 4:1
 Viscosity: 10 — 13 sec/20°C (68°F)
 Film thickness: 35 — 45µ
 Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm
2, 36 — 50 psi)Use section (block) paint for top coat.
 Paint in use (for each color):
Metallic paint
Hardener PB
Thinner T-306
 Mixing ratio:
Main agent vs. hardener = 10:1
 Viscosity: 10 — 13 sec/20°C (68°F)
 Film thickness: 15 — 20µ
 Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
7 Drying Not required.Dry at normal temperature [10 min. or more at
20°C (68°F)].
In half-dried condition, avoid dust, dirt.
8 Top coat paint (II) Not required.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
 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/cm
2, 36 — 50 psi)
9Drying60°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).
10 Inspection Paint check.
11 Masking removal Remove the masking in process No. 2.
EI-00038
(1)
(2)

EI-26
EXTERIOR/INTERIOR TRIM
Front Bumper
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 re-
stored 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.
2) Deep damage caused by scratching fences, etc.
A dent cannot be repaired but a whitened or swelled part can be removed.
Pro-
cess
No.Process name Job contents
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sand paper in a “feathering” motion.
3FinishResin section Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recom-
mended wax: NITTO KASEI Soft 99 TIRE WAX
BLACK, or equivalent.Perform either the same operation as for the
resin section or process No. 18 and subse-
quent operations in the “3)” section, depending
on the degree and nature of damage.
Polish the waxed area with a clean cloth after 5
to 10 minutes.
Pro-
cess
No.Process name Job contents
1 Cleaning Clean the damaged area with water.
2Removal of dam-
aged areaCut off protruding area, if any, due to collision, using a putty knife.
3 Sanding Grind the affected area with #100 to #500 sand paper.
4FinishResin section Coated section
Same as Process No. 3 in the “1)” section.Perform Process No. 12 and subsequent oper-
ations in the “3)” section.

EI-27
EXTERIOR/INTERIOR TRIM
Front Bumper
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)
Pro-
cess
No.Process name Job contents
1 Bumper removal Remove the bumper as required.
2 Part removal Remove the parts built into bumper as required.
3 Bumper placementPlace the bumper on a paint worktable as
required.
It is recommended that contour of worktable
accommodate internal shape of bumper.
(1) Bumper
(2) Set bumper section
4Surface prepara-
tionRemove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol).
5 CuttingIf 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.
(1) Paint surface
(2) PP base surface
(3) 20 — 30 mm (0.79 — 1.18 in)
(4) 3 mm (0.12 in)
6 Sanding (I) Grind beveled surface with sand paper (#40 to #60) to smooth finish.
7 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
8 Temporary weldingGrind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a sol-
vent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.
(1) Welded spot (Use heater gun and PP welding rod)
(2) PP base surface
(3) Beveled section
N
OTE:
 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-00038
(1)
(2)
EI-00235 (4)
(2) (1) (3)
EI-00236 (1)
(2)
(3)

EI-28
EXTERIOR/INTERIOR TRIM
Front Bumper
9 WeldingUsing a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam-
aged area.
(1) Melt hatched area
(2) Welding rod
(3) Section
N
OTE:
 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.
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.
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 nec-
essary.
Recommended primer: Mp/ 364 PP Primer
N
OTE:
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 20°C (68°F) for 10 to 15 minutes until primer is half-dry.
N
OTE:
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.)
15Primer surfacer
coatingApply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 min-
utes.
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
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
18Cleaning/
degreasingSame as Process No. 12. Pro-
cess
No.Process name Job contents
EI-00237 (1)(2)(2)
(3)
EI-00042

EI-29
EXTERIOR/INTERIOR TRIM
Front Bumper
19 Top coat (I)Solid color 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: 40 — 50µ
 Spraying thickness: 245 — 343 kPa
(2.5 — 3.5 kg/cm
2, 36 — 50 psi)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)
20 Leave unattended. Not required.Leave unattended at 20°C (68°F) for at least 10
minutes until the topcoated area is half-dry.
N
OTE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
21 Top coat (II) Not required.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)
 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/cm
2, 36 — 50 psi)
22 DryingAllow 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.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove the masking tape applied in Process No. 11 and 13.
25 Parts installation Install the parts on bumper in reverse order of removal.
26 Bumper installation Install the bumper. Pro-
cess
No.Process name Job contents

EI-30
EXTERIOR/INTERIOR TRIM
Rear Bumper
6. Rear Bumper
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the bolts and clips.
3) Remove the clips from bumper and bracket.
4) Remove the rear combination light assemblies
from each side. Combination Light Assembly.>
5) Remove the two clips from each side.
6) Remove the floor box.7) Remove the rear skirt trim.
8) Remove the bolt to remove bracket from
bumper.
9) Loosen the four nuts to remove rear bumper.
10) Disengage the clips to remove bumper upper
beam.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
General Description.>
C: REPAIR
Refer to front bumper repair. MOVAL, Front Bumper.>
EI-00043
EI-00044
EI-00045
EI-00047
EI-00046
EI-00048

EI-31
EXTERIOR/INTERIOR TRIM
Mud Guard
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.
B: INSTALLATION
Install in the reverse order of removal.
EI-00049

EI-32
EXTERIOR/INTERIOR TRIM
Cowl Panel
8. Cowl Panel
A: REMOVAL
1) Open the front hood.
2) Remove the wiper arm. MOVAL, Front Wiper Arm.>
3) Remove the clips to remove cowl side panels.
4) Loosen the clips to remove cowl panel.
B: INSTALLATION
Install in the reverse order of removal.
(A) Clip
EI-00050
EI-0725: (A)

EI-33
EXTERIOR/INTERIOR TRIM
Side Sill Spoiler
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.
B: INSTALLATION
Install in the reverse order of removal.
EI-00053

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