1999 SUBARU FORESTER service

2. Fuel Flap
A: REMOVAL AND INSTALLATION
1. FUEL FLAP
1) Remove bolts which hold hinge to vehicle body,
and detach fuel flap and hinge as a unit.
S5M0150
2) Install in the reverse order of removal.
CAUTION:
Make sure the clearance between the fuel flap
and vehicle body is equal at all points.
2. FUEL FLAP OPENER
1) Remove driver's seat and rear seat cushion.
2) Turn over the floor mat (driver's side).
3) Remove all clips which hold cable.
4) Disconnect cable (A) from pull handle (B).
5) Detach pull handle by removing bolts.
S5M0291B
6) Detach fuel lock holder by turning it.
7) Install in the reverse order of removal.
CAUTION:
After installing opener cable, ensure it moves
smoothly.
3. Front Bumper
A: REMOVAL AND INSTALLATION
1) Disconnect the ground cable from the battery.
2) Remove front fog light.
3) Remove the front grille.
4) Remove the extension of both sides.
S5M0152A
5) Remove the seven clips and then detach plate
(A).
S5M0397A
6) Remove under cover.
7) Remove the seven clips from under side of
bumper.
S5M0153
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3. Front Bumper

2. Fuel Flap
A: REMOVAL AND INSTALLATION
1. FUEL FLAP
1) Remove bolts which hold hinge to vehicle body,
and detach fuel flap and hinge as a unit.
S5M0150
2) Install in the reverse order of removal.
CAUTION:
Make sure the clearance between the fuel flap
and vehicle body is equal at all points.
2. FUEL FLAP OPENER
1) Remove driver's seat and rear seat cushion.
2) Turn over the floor mat (driver's side).
3) Remove all clips which hold cable.
4) Disconnect cable (A) from pull handle (B).
5) Detach pull handle by removing bolts.
S5M0291B
6) Detach fuel lock holder by turning it.
7) Install in the reverse order of removal.
CAUTION:
After installing opener cable, ensure it moves
smoothly.
3. Front Bumper
A: REMOVAL AND INSTALLATION
1) Disconnect the ground cable from the battery.
2) Remove front fog light.
3) Remove the front grille.
4) Remove the extension of both sides.
S5M0152A
5) Remove the seven clips and then detach plate
(A).
S5M0397A
6) Remove under cover.
7) Remove the seven clips from under side of
bumper.
S5M0153
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[W3A0]5-1SERVICE PROCEDURE
3. Front Bumper

8) Turn over the front mud guard of the front por-
tion and then remove bolt.
S5M0154
9) Remove bumper face and E/A foam.
10) Remove the four bolts and then detach the
back beam.
S5M0398
11) Remove the four bolts and then detach the
beam upper.
S5M0156
12) Install in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing the bumper.
4. Rear Bumper
A: REMOVAL AND INSTALLATION
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 connector.
5) Remove bolts and clips from under side of
bumper.
S5M0157
6) Remove bumper face and E/A foam.
7) Remove canister.
8) Remove bolts from bumper stay.
G5M0161
9) Remove rear bumper beam.
10) Install in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.
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4. Rear Bumper

8) Turn over the front mud guard of the front por-
tion and then remove bolt.
S5M0154
9) Remove bumper face and E/A foam.
10) Remove the four bolts and then detach the
back beam.
S5M0398
11) Remove the four bolts and then detach the
beam upper.
S5M0156
12) Install in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing the bumper.
4. Rear Bumper
A: REMOVAL AND INSTALLATION
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 connector.
5) Remove bolts and clips from under side of
bumper.
S5M0157
6) Remove bumper face and E/A foam.
7) Remove canister.
8) Remove bolts from bumper stay.
G5M0161
9) Remove rear bumper beam.
10) Install in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.
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4. Rear Bumper

6. Repair Instructions for Colored PP Bumper
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 obtain his or her understanding. Repair methods are outlined below, based
on a classification of the extent of damage.
A: 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.
2 Sanding Grind the repairing area with #500 sand paper in a ªfeatheringº motion.
3 FinishResin 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 ª(3)º section, depend-
ing on the degree and nature of damage.
Polish the waxed area with a clean cloth after
5 to 10 minutes.
B: DEEP DAMAGE CAUSED BY SCRATCHING FENCES, ETC.
A dent cannot be repaired but a whitened or swelled part can be removed.
Process
No.Process name Job contents
1 Cleaning Clean 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.
4 FinishResin section Coated section
Same as Process No. 3 in the ª(1)º section.Perform Process No. 12 and subsequent
operations in the ª(3)º section.
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6. Repair Instructions for Colored PP Bumper

C: 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 may not
be 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
1 Bumper removal Remove bumper as required.
2 Part removal Remove parts built into bumper as required.
3Bumper place-
mentPlace bumper on a paint worktable as
required.
It is recommended that contour of worktable
accommodate internal shape of bumper.
G5M0164
4Surface prepara-
tionRemove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable sol-
vent (NRM No. 900 Precleno, white gasoline, or alcohol).
5 CuttingIf damage includes 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 ªvee-
outº the affected area using a knife or grinder.
G5M0165
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.
8Temporary weld-
ingGrind 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:
IDo not melt welding rod until it flows out. This results in reduced strength.
ILeave the welded spot unattended until it cools completely.
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[W6C0]5-1SERVICE PROCEDURE
6. Repair Instructions for Colored PP Bumper

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.
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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.
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6. Repair Instructions for Colored PP Bumper