BODY AND EXTERIOR SUBARU. 1992 SERVICE MANUAL M_ MECHANISM AND FUNCTION 1. Body Construction 2, Cross-sectional Structure of Body 3. Quietness 6. Ventilation 7. Sunroof S SERVICE DAI 1, Body Datum Points... 2. Datum Dimensions . 42 3. Datum Points and Dimensions Concerning On-Board Aiming Adjustment (G.C.C. countries only) . 61 © COMPONENT PARTS . 62 1. Body Construction . 62 2. Front Hood and Hood Loc! . 84 3, Trunk Lid, Trunk Lid Opener and Fuel Flap . 5S 4, Front Bumper . 87 5, Rear Bumper . 58 6. Body Parts .. . 60 7. Outer Accessories . 62 8. Sunroof » 64 9, Rear Spoiler (TURBO) .. . 65 W SERVICE PROCEDURE . . 68 1, Hood . 66 2. Trunk Lid (including rear gate opener) . 67 3, Fuel Flep . 69 4, Front Bumper . 69 5, Rear Bumper ... n 6. Coating Method for PP Bumper R 7, Repair Instructions for Colored PP Bumper 74 8. Body Protector 7 9. Front Fender 78 10, Mud Guard and Arch Protector 78 11. Cowl Panel . 79 12, Molding 80 13, Front Grille . 82 14, Rear Molding (Sedan) .. 82 18. Sunroof 82 16. Rear Spoiler (TURBO). 85 T TROUBLESHOOTING 1. SunroofB-1_ [M100] BODY AND EXTERIOR M MECHANISM AND FUNCTION 1. Body Construction with high tensile strength steal sheets for light welght rigidity. The vehicle body is of monocoque construction, bult ieostlcied Sedan er we sh at Fig. 15-1_ {M200} BODY AND EXTERIOR 2. Cross-sectional Structure of Body Fig. 3BODY AND EXTERIOR 3. Quietness Silencers, dual-wall panels, sound-absorbing materials, etc. are utilized in conjunction with a high-rigidity and vibration/noise-proof body structure in order to provide a quiet passenger compartment. 1) Silencers They (= asphalt sheets) minimize the transmiss noise/vibration into the passenger compartment. 2) Dual-wall toeboard The toeboard is a dual-wall design consisting of an asphalt sheet placed between two steel panels to reduce the transmission of noise and vibration from the engine compartment to the passenger compartment, 5.1068 Fig. 41_ M400} BODY AND EXTERIOR effect and even thicker sound- 3) Sound-absorbing materials the sound-absorbin is used in the floor and toeboard ‘A unit construction type insulator is used respectively absorbing mater for the toeboard end rear bulkhead section to improve area. Rear bulkheed Insuietor ‘(Except fole-down type var saat) Front pillar Insulator. 51127 Fig. 5 4, Body Sealing Anytime the vehicle body has been repaired, etc., the affected holes should be properly plugged with the use Soalod parts of the specified plugs. All gauge holes and other holes used during the body manufacturing process are plugged to prevent entry of water and dust.BODY AND EXTERIOR [M501] 6. » 5. Rust Prevention The following information for the 4-door Sedan is basically the same as that for the Station Wagon and Touring Wagon. 1, Anti Chipping Coat (ACC) Application 1 Root ye » asttan Fig. 6 ne] Coe sectoral view Taped dion | Tonos | Renate 1 ‘Soden, Stetion Wagon ere Over 20 microns - 4 10:0m form » ‘Touring Wagon SEC.B Bett5-1_ [M501] BODY AND EXTERIOR Ne. (Gross sectional view ‘Applied section | Thickness Remarks 2 Front section of | Over 20 microns = F. fonder Bs-4t-4 Fig. 7 51129BODY AND EXTERIOR (mso2]_ 5-1 2. Stone Guard Coating (SGC) Application 1. fender F & R, Door 2, Upper srtace of side sill outer 5590 Fig. 8 No (ross sectional vow “Appliod socion | _Thiekness Remarks : F. fonder (Over 100 = microns F. door R. door Bs.3804 2 Upper surface of [Over 89 microne 7 sido sil outer |*: Over 100 microns p10 the rome height as 86Capoied tothe doors Bssse2 2 Front section of | Over 20 microns 7 Fenood Front section of F.tendor BS11904 Fig. 9 Bs.t1005-1_ [M503] BODY AND EXTERIOR 3. Polyvinyl Chloride (PVC) Application Thickness 600 fern 5.1071 Fig. 10 Europe model 5.1191 Fig. 11 Others 10BODY AND EXTERIOR 1 No. Imso3]_5- ‘Cross sectional view ‘Appliod section Thickness Remarks F. wheel house F fender Bracket F. sus. Mud guard whee! apror ‘Over 600 microns (Europe model) (Over 400 ‘microns (Others) Side ait Sige at outer [Over 300 iorore . quarter panel -R. quarter pansl outer 85.080.3| [over 600 microns Europe model) ‘Over 400 rmicrone (Others) R. quarter panel outer arch inner: whee! house Bracket F. sus. uppOr -R. wheel apron - (Over 600 micron Europe model) jover 400 Others) "5-1. [M503] BODY AND EXTERIOR Ne ‘Gross sectional view ‘Applied section Thickness. Remarks Europe mode! F. floor ‘ver 300 microns over 600 ‘miorons 5.118241 Jover 300 Over 400 ‘microns 12 R floor lover 100 [Europe model orty) *:0ver 300 rmieroneBODY AND EXTERIOR [M503]_5. ket inner Thickness: Over 200 mierons Fig. 12 13 6-060-7 No, (Grose sectional view ‘Applied section 7 a R.floor Riloor Jover 100 - Rear section ot | microns * Riloor *:Over 300 SEG eae +*:0ver 800 ‘microns (Europe ‘modal) "Over 400 MIN. (thers) 50, (97 5.1192BODY AND EXTERIOR 5-1 [M504] 4, Hot Wax Application Thickness 0 microns: Mma 20 microns: me 18 microns: ESB 85.1073, Fig. 13 14BODY AND EXTERIOR M504)_6-1 Unitimmiin) Gross sectional view ‘Appled secion | Thickness Peer and front | Over 20 microns = end section of F, ood rer 0 microns (Ory condition) tain MN og 1830) Bs.1074-1 Fbuikhoad [Over 207mierona | Europe model inside of duc) ony Over 60 microne (Pry eonetion) seo8 Bs10742) 2 Radiator panel [Over 20 microns | Europe model a 3 ower ony ze 2 g ‘Over 80 microns ze zo ihe (ry conaivor) sscc 5.1074] = Rear section of [Over 20 microns | Europe model 5 Fetencer ony ze Over 60 microne 58 (Ory conor) se0.0 Bs.1074) = E Lower esation of [ver 20 microre | Europe model 5 F-pillar ze 22 LF. itr over lover 80 rictore 5g 32 sie si nner : {Pry condition) so 2.8 ] ges see Bo.10745) 15{M504} BODY AND EXTERIOR Unit:mm(iny No. Grose eectionel view ‘Applied section | __ Thickness Remerks Side sit ‘Over 20 mievone = Jovar 80 microns g ory coneton) 2. z SECE = Bs10748 7 = Inner section of [Over 20 microna = finer doer and Back g ‘doce panel | Over 50 microne 2) (Ory condition) 5 Fe a2 Bs10747 @ quarter pane! [ver 20 microns | Europe model ony ver 50 microns (Ory condition) SEO Bs.10748) 2 Roar ond front | Over 20 microns = = end section of § a tank tid Over 59 microns: 2) ze e422 Dry condition) = 3 sec. as10769 rr a Fete [Over dO ions | Europe made D g (Over 60 microns whee! spon. ¢ z oxy condition) | seek as Bsaoret0 16BODY AND EXTERIOR No. ‘Gross sectional view ‘Roped section | Theknoss " Frame side FR Over 20 microns | Europe model = 3 ‘only i g Over 60 microns zg ° {Ory condition) ES se0.L, 5107811 2 = (Crosemember A [Over 20 microns | Europe model g ‘only s /Over 60 microns z (Dry condition z {Ory condition) seo 5.1074.12 8 [crossmember 8 [Over 20 microns | Europe model only (ver 60 microns (Ory condition) sec. = 85:1074-13 7 Frame spare tre [Over 20 microns | Europe model only Over 60 microns (Ory condition) SEC.P 5s.1074-14] 6 a Frame R floor | Over20 microns | Europe modal 8 only Acbaal pst: 2 ‘Over 60 microne FA {Ory condition) 3 2.8. se. see 85-1074:16| 7BODY AND EXTERIOR M504) Unit:ramiin) ry Grose scone ew ‘pled cocion | Tictnoss | Remaria |] 18 Brecket R cross: [Ovor 20 microns | Europe model member only JOver 80 microns {Ory condition) Bs-1074-16| 7 Reinforcement | Over 20 microns | Europe model tow board ‘only ‘Over 60 microns {Ory condition) $0.8 5.107417 18 3 skit (Over 20 microns | Europe modal 8 ‘only g ver 80 mirona Z| (Ory condition) 3 58:1074.18 18 Bracket pitching [Over 20 microns | Europe model stopper ‘only Over 60 microns Bulk hase (Ory condition) i Toe beard 2 Zz secu 5 B51074-19| 18BODY AND EXTERIOR M504) 5-1 Unit:mmtin) No, ‘Grose sectional view ‘Applied secion | _Thsiness | Remark AAA 20 quarter pane our quart panet [Over 20 microns | Europe model ony Over 50 microns (Ory conaton) a Reinforcement [Over 20 microns |” Europa model Frame side BF tis own hook ony JOver 60 microna a {Dry condition) $ Z LEM 2 Plate active | Over 20 miarons aaeeenaeae Over 80 mistone {Pry conetion) Fa Track ie down [Over 20 microns | Europe model ony a Frame. lor vor 60 microns zs. (01y conatior) Be Hook mutter 7% hood Wings [Over 18 microns (Ory condition)5-1_ [M504] BODY AND EXTERIOR Unitimnm(in) No. ‘cross sectional view “Applied sestion | Thickness Remarks Es Rgste Hinge [Over 15 microns = Body center (0ry condition) 85.1076) 28 ‘Around door [Over 16 microns = hinges {Ory condition) 5.10783) 7 Lower easton of [Over 20 microns | Europe model Concer pier center pila ‘only Over 50 microns {Ory condition! se0.2 es107427 _| Fig. 14 5.1074 20BODY AND EXTERIOR 5. Antl-rust Wax Application on Undercarriage M505] _5: ® Wools ‘Sections excluded from wax application @ Brake dae rotors @ Labels atfxed to the inside of the engine hood © Engine system com (A aight spray of wax mis 9 allowable) ® Engine (sight spray of wex mist Is allowable) oo — Hot wax [ESIET- rene Bs-1078 Fig. 15 No. ‘ross sectional vow “Ant-wost_] Thikness | Romerks ‘motel 7 Hot wax [Over60 [Wax not microns | applied to (ary conat-_|the compo- tion) rons inside the te boceus there ie tho possi that wax roist may 4omm contaminate (sri) brake rotors Not apie here and wheels. 2s.1076-1 2 ‘Conor see [Bituminous [Over 300 | Wax mist ion ot | wax microns | may setts Not speted here, | under oor {Ory conat- [orto salt. tion) exhaust ave Foor panel Bie Wax thick | Wox may Too boerd ese ie 160 [rot be microns |eppled to inside the | Bind spots oo: tunne.|of brackets, fe, In tune tal section. Side at exhaust SoA 25-1076 a5-1_ [M505] BODY AND EXTERIOR No. ‘cross ssctonal view ‘Applied see-] Antivust | Thickness | Remarks tion | material a [Rear side of [Biuninous [Over 300 |Wex may lundertioor | wax microns | not be {Dry condi | applied to A. suspen- tion) [whore com- sion compo: ponents are eonts Installed ctose Fuel tank ogether. covers Floor panel 85-1076-3 4 Tie house |Bkuminous [Over 150 [Air euspen- ax microns | sion ASSY Wiest {Ory condi- | ie covered apron, ion) by a protec: onder inner tor. and R quar- tor inner Strut ASSY, sec.c -1076-4 6 Rear section [Bituminous | Over 300 jorawo | wax ‘microns vehicle {Dry condl- tion) A. citforon- ial ASSY, Diarertiat member 25-1076) 6 Radiator [Hotwax | Over 80 panel lower ‘microns (Dry condi. tien) 85-1076-8 225-1. (M506) 6. Sealer and Adhesive Application BODY AND EXTERI! |OR ssior7 Fig. 17 7 carsales epind aia [esr retoil| Re : ae ear = esses 3 oo eae 7 eg eater = J se : ae f Co ( OD ‘Adhesive of ear Yo pase corBODY AND EXTERIOR Is05] 5-1 No. (Gross sectional view ‘Applied sec-] Antirust tion | material 7 Air euspon | — bs-1076-7| @ = 35-1076-8 Fig. 16 23BODY AND EXTERIOR 1506] 5-1 ; Codie ‘pia aoe zi oy ae Kast teins 7 ama ’ au cn nats Sonne sero 7 iatensiiit oe 7 tae oe weave ce are 7. oes) [ooo = a LS aca sioner Fig. 18 BS-10785-1_ [M507] BODY AND EXTERIOR 7. Galvanized Sheet Metal Application Corrosion preventive steel sheets are utilized where necess ry to protect the body a ‘Wagon eer arch : ear arch Front ptr tv sch Far floor (Si). Front pillar OUT- 3 ‘Sige eit OUT Front for CO ) 7 & Seared fe. " rare ie sor ur one As a so ust ‘Side frame. 2 Reivorcamen elorcament XP Toe boara) crosmenber raciet ® (ss eae a Se frame (Rex toon) racket oe aD 14 ; (Radiator) side frame) Beet rey rine Front side frame UPR. (Sie amo} Whee! apron UPA Frame LWA (Rater pane) Front suspension bracket Front wha pron svanzed bth sido c AAQUD onanses nom se ge sng Fig. 19BODY AND EXTERIOR M507] _5-1 Front fonda UIE «ren vo en ee Fig. 20 271_ [M508] BODY AND EXTERIOR 8. Rustproof Parts ‘Applied sec-] Antivust| Cross sectional view Ned se) Anal | Thickness 7 Front and [Rubber 7 Front Rear rear arch — Buty! SECA sec B5s91-4 3 Front sec. [TRE Plas | — tion of rar tc) arch A arch protector Protector 501-5 28BODY AND EXTERIOR [Msg] 5-1 ‘Applied eec-] Antirust No. Cross sectionat view tee | Ae, | Thickness | Remarks 4 Fusttank [PE (Plastic) | — = Protector Fuel tank 85.391-4) 5 Rear cross [EVA (Plas: | — = member of | tic) Front tear suspen 85.901.5| 6 Under cover | PP. (Plastic) | — = 5.592]5-1 _ (M508) BODY AND EXTERIOR Sc wctona Topload vor] Antot a Grose eoctonal view Hod ance} Antvust | ickness | Remarks - Under floor Plugs all foiee jexcopt r S water drain 0 eg te : eset Fig. 22 : 30BODY AND EXTERIOR [M600] 5-1 6. Ventilation Fresh alr Inlet port Front hood 85.001 Tet Tapa FOMTOT oe Alr outlet. por a fear seat x ow ear panel tn rank compartment e8 ‘Bumper ee ar quater 9 Rear quarter panel 1 ear ourticd ‘ws pnt iment 23 i manner ai one Cute gortOecaed on lt and right si) 35.1061 Fig. 24 315-1 [M701] BODY AND EXTERIOR 7. Sunroof 1. Construction ‘The following figure refers to the cross-sectional contours of the oof.BODY AND EXTERIOR 2, Drain Tube Layout [M702] 5-1 5.1082 Fig. 26 335-1 [S100] BODY AND EXTERIOR 5:1 18109) oro S SERVICE DATA 1. Body Datum Points Various master repair locations are established as datum points used during body repairs. in addition, guide holes, locators and indents are provided to facilitate panel replacement and achieve alignment accuracy. Loft and right datum points are all symmetrical to each other. @ : Master repair location Fig. 27[S100] _5-1 Ey) Fig. BODY AND EXTERIOR Fig. 296-1. {81005-1 [S100] BODY AND EXTERIOR rae ears Fig. 57 Fig. 60 [Sedan Sedan — \ ? Fig. 58 3680 SS Fig. ——— Fig. 69 Fig. 62 405-1. [S200] BODY AND EXTERIOR Wagon 2. Datum Dimensions Use a tram tracking gauge to measure all dimensions. If @ measuring tape is used, be extremely careful beceuse it tends to deflect or twist, which results in a false reading. ‘Tracking owuge 5.356, Fig. 69 ‘Wagon 35.288 | Fig. 71 5.357! Fig. 70 42ww BODY AND EXTERIOR [$201] 5-1 1, FRONT STRUCTURE 85-1050 Fig. 72 Qn — Oi + 1.296(61.02) o - © 881 (94.68) a On — O. + 024190.30) @. — @. + 1400 (96.49) ot gu): mm 3 2 St) ome B= $m 8 =F). nm oe) =e 8 - el) mm B= Seam 8 8) mn o ale ee oe SE mmm ‘Acsulfic character “R” of "L" rofors to the right or the lft All dimensions refer to the distance between the cen- ters of holes measured in a straight line.5-1 ($202) 2. CENTER STRUCTURE between hole centers. BODY AND EXTERIOR b. All dimensions refer to the distance between the ‘8. Esch dimension indicstes a projected dimension center of holes. an 14, i220] [239 lava (16.66)!408 (19.00) 206 (8.11) 159 (626)] HO. Lon 222 (8.74) aie a Ta = i a a4 S a HERES 8 s BTS + Dat ne Sat tango oe roca exo _| 699 2421 ||] 625 tary 72 6.) sa6 207 Te wea at Fig. 735-1 [S203] BODY AND EXTERIOR 3, DOORS AND REAR QUARTER 85-1001 Fig. 75 Unit nem finb @ — ©: mein ® > wpa) ® — © : ses ® ® = 761,90.75) | eee @ — © =: t272,6400) ® ©: 1206 6205) @ — © © 118006.29 8 ©. wpasg” | forte © — © = oon ® — © = s67:2007 ett ® © = 1296 6086) @ — © : veer 8 © ; ease @ — © =: srs @ ©; soeatsoz) — | Forwagon @ — © =: ross ® © + 10044105) @ — © = rapney ® ©: m1 0000) All dimensions refer to the distance between the con- ters of holes whon measured in a straight line. 46BODY AND EXTERIOR {sz02] 5-1 » All dimensions refer to the distance between the cen- ters of holes when measured in a straight line, acm Tad @ a 6 s © | z & oy Pee Net LIANG eH Yo RX LINE Ow 5 aaa ¢ =~] Ky i = a Fig. 74 45BODY AND EXTERIOR {s204] 5-1 » 4. FRONT WINDSHIELD AND REAR WINDOW 5-102 Fig. 76 nt een i Front pee 8 a ° 1 916(28.06) . = 2 J + sooaon ote e | 4990 (4457) & — one outa o. {: ewer one o |: meee @. — @ = 10354075) ®. 5 8 oo Ox — O& + 13904007 Or — O = treasan Ox — O_: 12906230 ‘) @. All dimensions refer to the distance between the b. A suffix character “R” or “L” refers to the right or canters of holes when measured ina straight line. _—the left. 475-1_ [S205] BODY AND EXTERIOR 5, TRUNK LID Unit: nen (i 1713 (28.07) 789 (30:28) + 671 (22.48) 634 (28.96) 960 (99.98) £1,800 (61.18) 85.204 Fig. 77 All dimensions refer to the distance between the cen- tors of holes when measured in a straight line. 6. REAR GATE nit: mn (i 870 (26.25) 5 1198 (47.01) +980 (87.80) 11406 (65.35) + 700 (27.68) £1,940 (62.76) 35.205 Fig. 78 All dimensions refer to the distance between the con- ters of holes when measured in a straight line. 48BODY AND EXTERIOR [8207] 5-1 Do. compartment 85.1099 Fig. 79 oi: etd eo -6 58 6138) a2 >seemee-< | eee aes lal 4087 42.01) He , ete eel 1,180 8.67) = Bh. tao son ecHuie e-@ 8 = 8), em dD ® - @ i tee ® -@ 1,261 (49.65) @ - & ®@® - 86 1070 (42.49) ® - a | jee © - 347 (37.28) ®@ - ®& @ - eit el 1,030 (40.85) eit e | 1.713 (6748) ® -@ 1,241 (48.86) @ - & 1,303 (64.84) @ = Gn): Jedan 1088(61.26) ® - © 1.432 (68.36) ® - e| Wagon 1,039 (40.81) @ - @& 1,133 (44.61) @ -— ® Sedan 1,018 (40.08) cae el: 70 (29.13) @s — @ Legon 1012 (098) © - & O - & 1.432 (68.38) ote e| 745 (29.38) @_e (ahs esa @ - & 1,258 (49.53) d a. All distance refer to the distance between the cen- ters of holes when measured in a straight line. b. A suffix character “R” or “L” refers to the right or the left. 495-1_ [$208] BODY AND EXTERIOR 8, LUGGAGE ROOM 900 Fig. 80 Unit: mm (in) @ = 0) times 6 > & |: samen 7 4 Me + 1.448 (68.81) C= OI. soretean O = @ + towrso Or — @& + 1104879) Or = @_+ eosis020 1. All distance refer to the distance between the cen. b. A suffix character “R’ or “L" refers to the right or ters of holes when measured in a straight line, the left. 50BODY AND EXTERIOR 3. Datum Points and Dimensions Concerning On-Board Aiming Adjustment (G.C.C. countries only) Hf headlamp aiming is misaligned due to damaged body panel, repair headlamp mating surface using body and headlamp datum points as a guide, Unit: ma ind 2 1,023 (40.26) £1,090 (42.91) Fig. 81 [S300] 5-1 be-1119 a. A suffix charecter “R” or “L" refers to the right or b. All dimensions refer to the distance between the the k centers of holes measured in a straight line. 515-1 [C101] BODY AND EXTERIOR C COMPONENT PARTS 1. Body Construction 1. SEDAN = OS Baas eo? Frame (rediator penal LWA) ‘Stay (Hood lock) ‘Skis pane! (radiator) sor Front sida frame (UPR) Wheel apron (UPR Front muspantion bracket Raloforcement (side frame) Frontside frame ‘Slee frame Aelntorcement (tovbourd) Toe Frame {front bulkheed) Front bulkhead ‘Support beam (steering) Bracket Doubler (front toot) Doubiar(forat floor) ‘Side sl (Inner) Front floor Creasmambae (front fleor) Bracket (front sext) cr SSLSSLERSSSSBVBRVBBsSsssaesstseeveasan- 40 Rese floor AI Reartoor (sds) 42 Rearekiet 43. Rear penal 44 Front pllar (inner) 45 Canter pillar anor) 48. Side allt rintoroe 47" Rewt quertar panel {inner 48 Front pillar ouw?) 49. Cente pillar (outer) 80 Drip rat sty 82. Bide tl (outer) 183. Rear quarter pane! (outer 54 Reinforcement (Bumper) 5. Brecker (Wether tank) 58 Bracket (Battery) 87 Rear erch IN Fig. 82 52BODY AND EXTERIOR [c102] 5-1 » 2. WAGON » 20. Front suspention brackst 24. Relntoreamant (ide fara) 22 Front de frame 23. Side frame 24 Relntorcomant (toe board) 25 Toe beard 26 Frama {front bulkhesd) @p) 27. Front bulkhead 28 Support beam (ering) 20 Bracket 30 Doubler (front toot) ® 231. Doubler {front tor) 33. Bide al (aver) 2 Front fleor 36. Croumember (front oor) Fig. 83 535-1 (C200) BODY AND EXTERIOR ( 2. Front Hood and Hood Lock DETAIL “0” { DETAIL “c” oe: 7 OX pee a Dera“ J 1 Lever AS8Y @ 2 Front hood 8 ~s 3 cations \ DETAIL “«" 4 Sea (Front panel 5 ip 7 rae - 7 Front heed sy WO es 10. Grommet oeralu"t" Ten! 12 Hoed butter 13 tater a ii - Tm (kam, ib) 18. Gamo er Ti: 23 ~ 42 (2.3 43,17 ~ 31) DeTAIL-0* n 5.1138 513.7) 17 Butter Fig, 84 54BODY AND EXTERIOR [c300]_ 5-1 » 3. Trunk Lid, Trunk Lid Opener and Fuel Flap 1 cover 2 Pull handle ASSY 18 Weatherstrip 19 Trunk ld roo ASSY 5.1097 Fig. 85 665-1 (C300) BODY AND EXTERIOR Fig. 86BODY AND EXTERIOR 4, Front Bumper Ic40o}_5-1 10 Breckor 11 Brecker (fog larmp) El | ® Tightening torque: N-m (kgm, fe1b) = NY TH: 69 — 118 (7 ~ 12, 51-87) 72: 5.4 — 9.3 (0.55 — 0.98, 4.0 — 6.9) Fig. 87 5.11985-1 [C501] BODY AND EXTERIOR 5, Rear Bumper 1. SEDAN “Tightening torque: Num (kgm, fb) Th: 69-118 (7 — 12, 61-87) 12: 5.4 —8.3 (0.55. 5 Brokat (Upper) 6 Stay 7 Splash guard TURBO mode! 12 85.1138 Fig. 88 58BODY AND EXTERIOR [c502] 5-1 1. Relnforeemant (sce) 2 Reerbeom 3 Molding ‘4 Bumper face 8 Bracket @ Splash guard Tightening torque: Nun (kim, fb) Ti: 69 — 118 (7-12, 81 — 87) 72: 8.49.3 (0.55 - 0.95, 4.0- 6.9) 85.1198 Fig. 89BODY AND EXTERIOR 5-1_ (C800) 6. Body Parts 5BODY AND EXTERIOR {C600]_5-1 —_———_——ee'— OES. et Fig. 915-1 [C700] BODY AND EXTERIOR 7. Outer Accessories5-1_ [C800] 8. Sunroof BODY AND EXTERIOR 1 2 3 4 8 8 Bssssardsrseoen Spacer Stopper Gast Ld ASSY Shim Drala ASSY Pipe grommet Motor ASSY Band Deflector ASSY Guide mat ASSY (F.H.) Gulde rll ASSY (LH) ‘Guide ral cover (F.H.) ‘Gulde ral cover (LH.) Harness ASSY Sun shede ASSY tip Draln tube (rear) Frame woatherstrip Control unit Pipe stopper Frame COMPL. Garnish Drain tube tfront) Becket (A) ‘Rear drain grommet (8.H.) ‘ear dean grommot (L.H.) Front drain grommat Handle Pipe ASSY Lent ewitcheosBODY AND EXTERIOR [700] _5-1 1. Reaniow miror (remote contra type) 2 Rearview mirror ETAL "E" Be-1103 Fig. 93 63BODY AND EXTERIOR (c900]_6-1 » 9. Rear Spoiler (TURBO) Fig. 965-1_ (WIAI] W > SERVICE PROCEDURE 1. Hood ‘The hood lock hes a dual locking design which consists of a main lock and a safety lock mechanismn. When the release knob located at the front pillar on the driver’s side is pulled back, the main lock is released through the cable attached to the knob, ‘The safety lock can be released by pushing the lever protruding above the front grille while opening the hood. REMOVAL 1. HOOD 1) Open front hood, and remove etteching bolt. 2) Detach front hood from hinges. Fig. 96 2. HOOD LOCK 1) Open front hood and remove front grille. 2) Remove bolts which secure lock ASSY to radiator panel, and remove lock ASSY. 3) Disconnect release cable from lock ASSY. 5-110) Fig. 97 BODY AND EXTERIOR 3, RELEASE CABLE 41) Remove front grille 2) Remove release cable from lock ASSY. 3) Remove cable clip from engine compartment. 4) Remove bracket from front pillar, wo Bett Fig. 98 B: POINTS TO CHECK 1) Check striker for bending or abnormal wear. 2) Check safety lever for improper movement. 3) Check other levers and spring for rust formation and unsmooth movement. B5-1104 Fig, 99BODY AND EXTERIOR C: INSTALLATION Installation is in the reverse order of removal. Align the center of striker with lock during installa- ion. Make sure sefety lever is properly caught by striker under the hood’s own weight. b. Route hood lock release cable and hold with clips. ©. Adjust buffer ASSY on each end so that main lock is epplied securely when hood is released from a height of approx. 20 mm (0.79 in). cable, ensure it operates smoothly. @. Apply grease to sliding surfaces of parts. 85-1105 Fig. 101 D: ADJUSTMENT 1) Fore-aft and left-right adjustments Loosen striker mounting bolts and adjust fore-and-aft position of striker. Do not adjust striker position using the lock. Doing so may result in @ miseligned front grille. 2) Up-down adjustment Make up-and-down adjustment of striker only when hood does not properly contact buffer or hood is not flush with fender, or when release cable does not prop- 67 Iweat] 5-1 erly operate. Adjustment can be made by adjusting the stroke length of striker after lock ASSY mounting screws are removed, Radiator panel 85-1108 Fig. 102 2. Trunk Lid ‘A: REMOVAL 1, TRUNK LID Open trunk tid. Remove trunk lid mounting bolts and detach trunk lid from hinges. 6-117| Fig. 103BODY ANI {w2a2} 2. TORSION BAR 1) Open trunk lid, Remove torsion bars from hinge links, using REMOVER (927780000). 2) Remove the torsion bar from bracket using REMOVER (927780000). Be coreful because torsion bi when released. 3) Remove the left and right torsion bers. Be careful because trunk tid drops under its own weight when torsion bars are removed. quickly swings back ‘Trunk torsion bar remover 25-118) Fig, 104 3. TRUNK LID 1.OCK ASSEMBLY AND KEY CYL- INDER 1) Remove rod of lock ASSY from rod holder of key lock ASSY. 2) Remove bolts which hold lock ASSY and remove lock ASSY. a. Always remove rear skirt trim panel beforehand, 0 equipped. b, Be careful not to bend opener cabl 3) Remove clip and detach key cylinder from trunk lid jes is Fig. 105 jD EXTERIOR 4, TRUNK LID OPENER 1) Remove driver's seat, rear seats, center pillar lower cover, floor mat, rear arch cover and side sill cover (on the driver's side). 2) Remove all clips which hold cable. 3) Disconnect cable from pull handle ASSY. 4) Remove bolts and detach pull handle ASSY. 8) Loosen bolts which hold lock ASSY, and remove it. 8) Remove striker from trunk lid. 7) Disconnect cable from stri Be careful not to bend or break cable. Fig. 106 B: INSTALLATION Installation is in the reverse order of removal. #. When installing cover to pull handle assembly, observe the following: © Be careful not to catch harn ‘© Engoge pull handle assombly pawis firmly. b, After installing opener cable, ensure it moves ‘smoothly. €. Apply a coat of grease to the rotary section of hinges and contact surfaces of torsion bars. d. Apply grease to sliding surfaces of lock ASSY and striker. Fig. 107 68BODY AND EXTERIOR 1waao]_ 5-1 : ADJUSTMENT eG My hs oO o 4, TRUNK LID osTaiL "0" 1) To adjust left-right lid positioning, loosen bolts which hold trunk lid to hinges. = Zz @ @ 2) To adjust up-down lid alignment, place washer(s) 4 . between trunk lid and hinges or move trunk lock ASSY up or down. ® S 1 cone 2 Pallhance ASS 3 cae —_ Lock ASSY Fig. 110 B: INSTALLATION 85-254 Fig. 108 3. Fuel Flap : REMOVAL 1, FUEL FLAP Remove bolts which hold hinge to car body, and detach fuel flap and hinge as @ unit. Fu! Bot Fig. 109 2. FUEL FLAP OPENER 41) Remove driver's seat, rear seats, center pillar lower cover, floor mat, rear arch cover/rear quarter trim (wagon), and side sill cover (on the driver's side). 2) Remove all clips which hold cable. 3) Disconnect cable from pull handle. 4) Detach pull handle by removing bolts. 8) Detach fuel lock holder by turning it. Installation is in the reverse order of removal. ‘a. When installing cover to pull handle assembly, ‘observe the following: ‘© Be careful not to catch harness, ‘© Engage pull handle assembly pawls firmly. b, Make sure the clearance between fuel flap and cor body is equal at all points. ¢. After installing opener cable, ensure it moves smoothly. 4. Front Bumper A: REMOVAL 1) Disconnect the 2) Remove the canister. 3) Remove the mud guard. 4) Remove bolts and nuts from side of bumper. 5.296) Fig. 117 69‘5-1 W480} 5) Remove clips from lower side of bumper. BODY AND EXTERIOR INSTALLATION .S— To install the front bumper, reverse the above removal procedures, , Be extremely careful to prevent scratches on bumper face as it is made of resin. b, Be careful not to scratch the body when removing or installing the bumper. ©. To facilitete installation of front bumper, attach hook (located at stay) to body panel. el Fig. 112 6) Remove bolts (engine compartment side) from bumper stays, Fig. 113 7) Remove bumper ASSY. Fig. 115 C: INSTALLING THE BUMPER MOLDING 1) Clean the groove on the surface of the bumper. Remove foreign matter with white gasoline or methanol, and then wipe with a clean cloth. 2) Apply a thin coat of primer (3M-brand K-50) using a brush or felt, and allow the coated area to dry for 110 5 minutes. (if humidity is above 65%, allow the affected area to dry for at least 10 minutes.) Apply primer to the dosignated area only (shown in ‘the figure on the under). Areas coated with primer will shi affect the appearal nd adversely me application area Fig. 116 70BODY AND EXTERIOR 3) install the molding, Peel the separator from one end of the molding and insert the end of the molding into the hole in the end of the bumper, While gradually peeling the separator from the molding, press the molding against the groove. @, Be careful not to allow the end of the molding to ride over the sharp-bend corner. Otherwise, the mold- ing may lift and peel off. b. Maintain the temperature of the molding and bumper above 15°C (59°F) during operation. Lower ‘temporatures reduce adhesive power of the molding. Do not contaminate the adhesive surface with fingerprints, etc. 4) Press the molding against the mating surface. Using @ suitable roller, press the molding along the groove in the bumper. Pressing force: 49.N (5 kg, 11 Ib), min 5. Rear Bumper [ws80} 5-1 5) Remove bumper ASSY. 2. WAGON 1) Open rear gate and rear quarter trim lid. 2} Remove bolts and nuts from side of bumper. 5-200) Fig. 118 3) Remove bolts from bumper stays. 4) Remove bumper ASSY. A: REMOVAL B: INSTALLATION 1. SEDAN 1) Open trunk id, Remove trunk trim panel clips and detach trim. 2) Disconnect the license plate light connector. 3) Remove bolts and nuts from side of bumper. 6.1108 To install the rear bumper, reverse the above removal procedures. a. Be extremely careful to prevent scratcher bumper face as it is made of resin. b, Be careful not to scratch the body when removing or installing bumper. on Fig. 117 4) Remove bolts from bumper stays. n1. {We00] BODY AND EXTERIOR 6. Coating Method for PP Bumper PROCESS STEPS Prose | process name Job conors [Bumper mounting ‘Set bumper on paint workable if requirad, Uso aint worktable conforming to inner shape of ‘bumper when possible. ‘Set bumper section 502 Fig. 119 ‘Mask specified part fleck base) with masking tape. ‘Use masking tape for PP {example, Nichiban No. 72 oe eee '583, tc). For details, sae the following figures. 3 [ Degreasing. cleaning _|Clean all parts to be painted with white gasoline, normal alcohol, ete to remove dit. ol fat, etc | Primor paine Apply primer one to all parts to be painted, using air gun, Use primer (clea. ‘Dry at normal temperature {10 to 16 min. at 20°C (68°F) 5 Diving In hol-dried condition, PP primer paint is dissolved by solver, e.g. thinner, ete, ‘Therefore, if dust or dit must be removed, use ordinary aleohol, ate Solid color Metalic color ‘Uso section (block) paint for top coat. =~ '* Paintin use {for each color) © Paint in use (for each color) Solid paint Metalic paint i Hardanor PB. Hardener PB. 8 |Top coat peint ‘Thinner T-201 “Thinner T-308 ‘Mixing ratio: Main agent ve. hardener = 4:1 |* Mixing ratio: Mein agent ve. herdonar = 10: 1 '* Viscosity: 10 — 13 s0c/20°C (88°F) Viscosity: 10 — 13 sec (68°F) '¢ Flim thicknoss: 35 — a8). Je. Film thickness: 16 — 292 /* Spraying pressure: 245 — 243 kPa (2.5 — 3.5 |@ Spraying pressuce: 206 — 343 kPa (25 — 35 kolem®, 38 — 50 psi) kalem?, 36 — 60 psi) Dry et normal temperature (10 min, or more at 7 |Deving Not required 20°C (es). In half-dried condition, avoid dust dit ‘Apply a clear coat to parts with top coat (), three times, at 6 — 7 minute intervals, © Point inuse Metalic paint Hardener PB 8 |Top cost a Not required. ‘Thinner 7-308 '¢ Mixing ratio: Clear vs, hardener = 6 ; 1 '¢ Viscosity: 14 — 16 sec/20°0 (687) '¢ Film thicknoss: 25 — 30 '* Spraying pressure: 245 — 343 KPa (26 — 3.5 kalem?, 38 — 60 psi) ae oe [60°C (140°), 60 min, oF 80°C (176°), 20 min IY higher then 80°C (178°), PP may be deformed. Keep maximum temperature of 80° (16°F) 10 _ [inspection Paint check, 11 [Masking removal [Remove masking in process No.BODY AND EXTERIOR {we0o] 5-1 Unit em (a) 3. (012) 3.012) 3012) QO Masking tape Ana Masking tape a 15 0059) I seribed tno 3 (0.2) 51109 Fig. 120 735-1 [W700] BODY AND EXTERIOR 7. Repair Instructions for Col- point to the customer and get an understanding about the matter. ored PP Bumper Repair methods are outlined below, based on a classi- All PP bumpers are provided with @ grained surface, fication of the extent of damage. and If the surface is damaged, it cannot normally be 4. jINOR DAMAGE CAUSING ONLY A restored to its former condition. Damage limited to hallow scratches that eause only a change in the lustre. CHANGE IN THE LUSTRE OF THE BUMPER DUE of the base material or coating, can be almost fully TO ALIGHT TOUCH restored, Before repairing a damaged area, explain this Almost restorable. case] process name Job contents 1+ [Gearing Glan tho aren to be opaed using water 2 [sending (Grind tho repairing area with #00 sandpaper in 6 “Teathering” mation. | Resin soon Coad soaion Fopantady apply wax to te afeciad eran using @ oft lth (ouch a8 tana. ertoom eit the same operation as forth resin 2 [rin Focommended war: NITTO KASEI Sof 66 TIRE | oztion or process No. 18 and eubeecuent opee- WAX BLACK, of oquvalent tone In tha 3)" soon, depending an the doaroo Posh he waxed area win @ dean coh afer 51> rd natu ot damese, ( 10 mines 2. DEEP DAMAGE CAUSED BY SCRATCHING —_—A dent cannot be repaired but a whitened or swelled FENCES, ETC. part can be remove Process Ra? | Process name, Job contents 1 [Cleaning [Clean damaged area with water Removal of dem | exe oft prouding It any, dus to colision, using @ putty kale [Grind the effected area with #100 To #600 sandpaper. Resin section ‘Gosted section 4 [rn ian cnt operate Berea Prcens N.3inta "(i ecion [Pena Paves No 12 and uber opal 3. DEEP DAMAGE SUCH AS A BREAK OR HOLE really worth the expense. (The surface, however, will ‘THAT REQUIRES FILLING become almost flush with adjacent areas.) Much of the peripheral grained surface must be sacri. Recommended repair kit: PP Part Repair Kit (NRM) ficed for repair, and the degree of restoration is not Process | process name Job contents 1__[Bumper removal | Remove bumpar as required. 2 [Part removal Remove parte built into burnper aa required, ‘sumper Place bumpor on @ paint worktable as required, tis recommended thet contour of worktable ‘accommodete internal shape of bumpar. 3 [Bumper placer Set bumper section 185.202 Fig. 121, Femove dust, off ete fom areas to be repaired and surrounding areas, sing a eutabie sowvent (NRW No, 800 Preclano, white gasoline, or alzohol). q 4 | Surface preparation 4BODY AND EXTERIOR [w703]_5-1 Process Reet | Process name Job contents 20 —3040.79— 1.18) Unit: mm tin} nature of damage is cracks or Roles, cut a guide ‘lt of 29 to 30 mm (0.78 101.18 in) in length along 8 |cuting tha crack of hole up to the bumpers base surface. 32) ‘Then, bevel or "ves-out” the effected area using PP ate iife‘or grinder. surtace 85.304 [Sanding [Grind beveled surface with sandpaper (#40 to #60) to smooth finish 7 [Cleaning ‘Clean the sanded surface with the same solvent as used in Process NO. a | Temporary welding “Gnd the sido just opposite the beveled Temporary spotawvald the side, using a ‘with sandpaper (#40 to #60) and clean using a solvent. ‘welding rod and heator gun. lalded spot (Use heater gun and PP welding rea) ‘bate surfoce 85.905 Fig, 123 ‘Do not melt welding rod until it flows out. This results in redueed strength. 1. Leave the welded spot unattended until It cools completely. 2 | Welding ‘Using « hester gun and PP welding rod, weld the baveled spot wile mating the rod and damaged area, Wilding rod Welding tod, ‘Matt hotebed Section Fig, 124 1, Mek the sections indicated by hatched ares. Bb, Do not melt welding rod until i flows out, In order to provide strength. Always keep the heater gun 1 to 2 em (0.4 to 0.8 in) away from the welding spot. Leave the welded spot unattended until it cools completely. 765-1 (W703) Process BODY AND EXTERIOR SE ale TE Bota satbenSa uate acini har am gow as petal _—_O_ =» wo ‘Sand the welded spot smooth with #240 sandpaper. " ‘Mask the black substrate section (as indiceted in the figure, using masking tape, Recommended masking tape: Nichiban No, 693 or equivalent For dotalls, 600 the figures showing the masking portions. @ Completely clean the entive costed ares, using solvent similar to thet used in Process No. & ‘Apply @ coat of primor to the repaired surface and its surrounding areas. Mask these areas, i necessary, Recommended primar: No. 364 PP Primer Be cure to apply one coat of primer at a spraying preseure of 245 to 949 kPa {25 to 2.5 kg/em?, 96 to 13 | primer coat HG |50 pe) with @ spy gun. eave the rapalied area unaiiended at 20° (68°F for 10 To 16 minutes until primer haltary. W dirt or dust comes in contact with the costed aree, wipe it off with m cloth damp-ened with aleo- 14 [Leave untended | hol. (Do not use thinner since the costed eres tends to melt) [Apply a coat of primor surfacar to the repaired ares two or thee times al en interval of 8 10 & minutes, Recommended surfacer:® UPS 300 Flex Primer eee '¢ No, 308 UPS 300 Exclusive hardener 16 ‘¢ NPS 725 Exclusive Reducer thinrer) Posting ‘© Mixing ratio: 2 : 1 (UPS 200: No 203) ‘© Viscosity: 12 ~ 14 s0o/20°C (68°F} ® Coated film thickness: 40 — BQ. \ 16_[Biving [low the costed surface to dy for 60 minutes a 20% (607) [or 50 minuson at OPC [NAO 47_| Sanding (0, ‘Sand the costed surface and its surrounding aress using #400 sandpaper and water 16 __|Cleaning/ degreasing [Same as Process No. 12. Solid color Metalic color Use a “block” coating method. = '* Recommended paint: . Suneryl (8) No, 307 Flax Hardener 7 SC Reducor fthinner) pee eee (© Mixing ratio: 3:1 - (Sunciyk: No. 307) ‘© Viscosity: 11 — 13 s0cj20°¢ (6e*F) ~ ‘© Coated film thickness: 40 — 50y ‘Coated frm thicknoss: 20 — 304 ' Spreving thickness: 245 — 943 #Pa (2.5 — 3.5 - kg/emt, 36 — 60 pai) eave unettonded at 20% (867) for atleast 10 min- tes uti the topcoated area is half-dy. 20 |Leave unatended | Not required. Be careful to keop dust or dirt from joming in contact with the affected ar 78BODY AND EXTERIOR [wsB0] 5-1 Process name Job contents [Apply a clear coat three times at an Itawval oF 31 5 micwsos. '¢ Recommended paint: ‘80740 Overley Clesr No. 207 Flex Hardener 'SC Reducer (thinner) Je Micing ratio: 3:1 (SC710: No. 307) 1 Viscosity: 10 — 19 sec/20°C (68) ‘© Gosted film thickness: 20 — 30 ‘© Spraying prossure: 245 — 949 Wa (2.6 — 35 kgfem?, 36 — 60 psi) “Rlow the coated surface 1 dry at 20° (68°F Tor wo hours or 60°C (140) for 30 minutos, Top cost) Not required. Diving Do not allow the tempersture to exceed 80°C (1767) since this will deform the PP eubstrate, Tnepection ‘Garofully check the condition of the repaired aroa. Masking removal | Remove masking tape applied in Prozess No. 11 and 13. Parts instalation | Instal parts on bumper in reverse order of removel. [Bumper instalation [Install bumper. 8. Body Protector Type : REMOVAL ani 5.310 Fig. 128 Type A: Protector is attached to car body with clips. Remove mud guard and door inner trim, and detach protector by pushing clips pawl from inside, Type B: Remove the nuts. Type C: Protector is attached to car body with clips and double-sided adhesive tape. Peel off double-sided adhesi Fig. 126 ‘Type B tape. B: INSTALLATION Type A: Align the clips with holes in the ear bedy and insert them, Then, tighten the nuts. Type B: Tighten the nuts. ‘Type C and C’: Position bushing in car body hole to install clip C, Remove tack paper from double-sided adhesive tape. as.000/ When clip C is aligned with car body hole, push in the clip. ae te install bushing to clip C’ and position in the hole. ') Install clips in standard holes first. 7