2004 SUBARU FORESTER Service Repair Manual

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Page 497 of 2870

SUBARU FORESTER 2004 Service Repair Manual EI-21
EXTERIOR/INTERIOR TRIM
Hood Grille
6) Install the hood duct with clip (A) and five screws.
C: INSPECTION
Make sure that the clip is firmly engaged.
Make sure that there is no abnormal gap at who

Page 498 of 2870

SUBARU FORESTER 2004 Service Repair Manual EI-22
EXTERIOR/INTERIOR TRIM
Front Under Cover
4. Front Under Cover
A: REMOVAL
1) Lift-up the vehicle.
2) Loosen the bolts, remove the clips, and then re-
move the under cover.
B: INSTALLATION
Install

Page 499 of 2870

SUBARU FORESTER 2004 Service Repair Manual EI-23
EXTERIOR/INTERIOR TRIM
Front Bumper
5. Front Bumper
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Loosen the two clips to remove the mud guard and
front under cover.
3) Turn over th

Page 500 of 2870

SUBARU FORESTER 2004 Service Repair Manual EI-24
EXTERIOR/INTERIOR TRIM
Front Bumper
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
<Ref. to EI-4, FRONT BUMPER, COMPO-
N

Page 501 of 2870

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 w

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)

Page 502 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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

Page 503 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 restorati

Page 504 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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) Sect

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

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