SUBARU TRIBECA 2009 1.G Service Workshop Manual

EI-19
Mud Guard
EXTERIOR/INTERIOR TRIM
4. Mud Guard
A: REMOVAL
1) Remove the wheels.
2) Loosen the screws and clips to remove mud
guard.
•Front mud guard
•Rear mud guard
B: INSTALLATION
Install in the reverse order of removal.
EI-01266
EI-01267

EI-20
Front Grille
EXTERIOR/INTERIOR TRIM
5. Front Grille
A: REMOVAL
1) Remove the front bumper. MOVAL, Front Bumper.>
2) Remove the screws, and remove the front grille
from bumper face.
B: INSTALLATION
Install in the reverse order of removal.
EI-01262

EI-21
Front Bumper
EXTERIOR/INTERIOR TRIM
6. Front Bumper
A: REMOVAL
1. FRONT BUMPER FACE
1) Remove the front upper cover.
2) Turn over the front mud guard, and remove the
clips connecting the fender and bumper.
3) Remove the clips at the lower side of bumper.
4) Disconnect the fog light connector. (Model with
fog light)
5) Remove the knotch on the bumper face side
from guide bracket (A)
CAUTION:
Be careful when removing, as pulling forcefully
can damage the knotch on the bumper face
side.
NOTE:
Lift the bumper face upward, and removing in the
order of (B), (1)-(5) of the fender side, will make it
easier to remove.
6) Remove the clips, and then remove the bumper
face from vehicle body.
7) Remove the front grille from bumper face. to EI-20, REMOVAL, Front Grille.>
8) Remove the fog light from bumper face. LI-17, REMOVAL, Front Fog Light Assembly.>
EI-01268
EI-00572
EI-00573
EI-01379
(1)(2)
(3)
(4)
(5)
(B)(A)
EI-01378

EI-22
Front Bumper
EXTERIOR/INTERIOR TRIM
2. FRONT BUMPER BEAM ASSEMBLY
1) Remove the front bumper face.
2) Remove the energy absorber foam from bumper
beam.
3) Remove the bolts, and remove the bumper
beam assembly from vehicle body.
NOTE:
After all bolts are removed, raise the whole bumper
beam a little to remove it from vehicle body.
B: INSTALLATION
1. FRONT BUMPER FACE
1) Mount the bumper face securely in the gap be-
tween guide bracket (A) and fender (B).
2) Install in the reverse order of removal.
2. FRONT BUMPER BEAM ASSEMBLY
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion”. NENT, General Description.>
EI-01271
EI-01272
(A)
(B)

EI-23
Front Bumper
EXTERIOR/INTERIOR TRIM
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Process
No.Process name Job contents
1Bumper installation
Place the bumper on a paint worktable as
required. Use the paint worktable conforming
to inner shape of bumper if 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/cleaningClean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
4Primer paint Apply primer to all parts to be painted, using spray gun. Use primer (clear).
5Drying
Dry at normal temperature [10 — 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.
6Top coat paint (I)
Non-colored Metallic paint
Use section (block) paint for top coat.
•Paint to be used (for each color):
Solid paint
Hardener PB
Thinner T-301
•Mixture ratio:
Main agent vs. hardener = 4:1
• Viscosity: 10 — 13 sec./20°C (68°F)
•Film thickness: 35 — 45 µ
•Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Use section (block) paint for top coat.
•Paint to be used (for each color):
Metallic paint
Hardener PB
Thinner T-306
•Mixture ratio:
Main agent vs. hardener = 10:1
•Viscosity: 10 — 13 sec./20°C (68°F)
•Film thickness: 15 — 20 µ
•Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
7Drying Not required.
Dry at normal temperature [at least 10 min. at
20°C (68°F)].
In half-dried condition, avoid dust, dirt.
8Top coat paint (II)Not required.
Apply a clear coat to parts with top coat paint
(I), three times at 5 — 7 minutes intervals.
•Paint to be used:
Metallic paint
Hardener PB
Thinner T-301
•Mixture ratio:
Clear coat vs. hardener = 6:1
•Viscosity: 14 — 16 sec./20°C (68°F)
•Film thickness: 25 — 30 µ
•Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
9Drying
60°C (140°F), 60 min. or 80°C (176°F), 30 min.
If higher than 80°C (176°F), PP may become be deformed. Keep maximum temperature below
80°C (176°F).
10 Inspection Check paint.
11 Removal of masking Remove the masking tape applied in procedure 2.
EI-00234(2)
(1)

EI-24
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 re-
stored to its former condition. Damages limited to the shallow scratches that cause only a change in the luster
of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this
point to the customer and obtain 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 luster of the bumper due to a light touch
Almost restorable.
2) Deep damage caused by scratching with fences etc.
A dent cannot be repaired but a whitened or swelled part can be removed.
Process
No.Process name Job contents
1Cleaning Clean the area to be repaired using water.
2Sanding Grind the repairing area with #500 sand paper in a “feathering” motion.
3Finish
Resin section Coated section
Repeatedly apply wax to the affected area
using soft cloth (such as flannel). Recom-
mended wax: NITTO KASEI Soft 99 TIRE
WA X B L ACK , o r e qu iva le n t.
Perfor m either the same process as for the
resin section or process No. 18 and subse-
quent in the 3) section, depending on the
degree and nature of damage.Po li sh t he waxed ar e a w i t h c le a n c lo t h a f te r 5
— 10 minutes.
Process
No.Process name Job contents
1Cleaning Clean the damaged area with water.
2Removal of dam-
aged areaCut off protruding area, if any, due to collision, using a putty knife.
3Sanding Sand the affected area with #100 — #500 sand paper.
4Finish
Resin section Coated section
Same as step 3 in the “1)” section.Perfor m step 12 and subsequent operations in
the “3)” section.

EI-25
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. 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.Process name Job contents
1Bumper removalRemove the bumper as required.
2Removal of partsRemove the parts built into bumper as required.
3Bumper placement
Place the bumper on a paint worktable as
required.
It is recommended to use the paint worktable
conforming to internal shape of bumper.
(1) Bumper
(2) Set bumper section
4Surface prepara-
tion
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol, etc.).
5Cutting
If the damage is a crack or a hole, 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 base
surface. Next, use a knife or grinder to carve a
V- s h a p e d g r o o ve i n t h e a r e a f o r r e p a i r.
(1) Paint surface
(2) PP base surface
(3) 20 — 30 mm (0.79 — 1.18 in)
(4) 3 mm (0.12 in)
6Sanding (I) Grind beveled surface with sand paper (#40 — #60) to smooth finish.
7Cleaning Clean the sanded surface with the same solvent as used in Procedure 4.
8Temporary welding
Grind the side just opposite the beveled area with sand paper (#40 — #60) and clean using a
solvent.
Te m p o r a r i l y s p o t - w e l d t h e s i d e , u s i n g P P w e l d i n g r o d a n d h e a t e r g u n .
(1) Welded point (Use heater gun and PP welding rod)
(2) PP base surface
(3) Beveled section
NOTE:•Do not melt welding rod until it flows out. This results in reduced strength.
•Leave the welded spot unattended until it cools completely.
EI-00234(2)
(1)
EI-00235
(4)(2)
(1)(3)
EI-00236
(1)
(2)
(3)

EI-26
Front Bumper
EXTERIOR/INTERIOR TRIM
9Welding
Using a heater gun and PP welding rod, weld the beveled spot while melting both the rod and
damaged area.
(1) Welding rod
(2) Melt hatched area
(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.
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/degreas-
ingCompletely clean the entire coated area, using solvent similar to that used in Procedure 4.
13 Primer coating
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 a coat of primer using a spray gun at a pressure of 245 — 343 kPa (2.5 — 3.5
kg/cm2, 36 — 50 psi).
14 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 dampened with alcohol.
(Do not use thinner since the coated area tends to melt.)
15Primer surfacer
coating
Apply primer surfacer to the repaired area two or three times at an interval of 3 - 5 minutes.
Recommended surfacer:
•UPS 300 Flex Primer
•No. 303 UPS 300 Exclusive hardener
•NPS 725 Exclusive Reducer (thinner)
•Mixture ratio:
2 : 1 (UPS 300 : No. 303)
•Viscosity: 12 — 14 sec./20°C (68°F)
• Coating film thickness: 40 — 50 µ
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.
Process
No.Process name Job contents
(1)
(2)
(2)
(3)
EI-00237
EI-00042

EI-27
Front Bumper
EXTERIOR/INTERIOR TRIM
18Cleaning/degreas-
ingSame as Process No. 12.
19 Top coat (I)
Non-colored Metallic paint
Use a “block” coating method.
•Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
•Mixture ratio:
Suncryl (SC) vs. No. 307 Flex Hardener = 3 : 1
•Viscosity: 11 — 13 sec./20°C (68°F)
• Coating film thickness: 40 — 50 µ
•Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Use a “block” coating method.
•Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
•Mixture ratio:
Suncryl (SC) vs. No. 307 Flex Hardener = 3 : 1
•Viscosity: 11 — 13 sec./20°C (68°F)
•Coating film thickness: 20 — 30 µ
•Spraying pressure: 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 topcoat area is half-dry.
NOTE:
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)
•Mixture ratio:
Suncryl (SC) vs. No. 307 Flex Hardener = 3 : 1
•Viscosity: 10 — 13 sec./20°C (68°F)
•Coating film thickness: 20 — 30 µ
•Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
22 Drying
Allow the coated surface to dry for two hours at 20°C (68°F) or 30 minutes at 60°C (140°F)].
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.
24Removal of mask-
ingRemove the masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on the bumper in reverse order of removal.
26 Bumper installation Install the bumper.
Process
No.Process name Job contents

EI-28
Rear Bumper
EXTERIOR/INTERIOR TRIM
7. Rear Bumper
A: REMOVAL
1. REAR BUMPER FACE
1) Remove the clips, and then remove the reflector.
2) Turn over the mud guard, and remove the clip
(A) and (B) inside wheel house and in the lower
side of bumper.
3) Remove the clips on the lower side of rear
bumper.
4) Remove the rear bumper from vehicle body.
CAUTION:
Do not pull with a excessive force. Otherwise
the bracket installation area may be damaged.
NOTE:
When removing the bumper face from bracket, it is
easier to remove from the end in order.
2. REAR BUMPER BRACKET
1) Remove the rear bumper face from vehicle
body.
2) Remove the corner bracket.
3) Remove the lower brackets from vehicle body.
3. REAR BUMPER BEAM ASSEMBLY
1) Remove the rear bumper face.
2) Remove the energy absorber foam.
3) Remove the nuts, and remove the bumper beam
assembly from vehicle body.
EI-01273
EI-00580
(A)
(B)
EI-01274
EI-01275
(2)(3)
(1)
EI-01276
EI-01277
EI-01278