5-1 BODY AND EXTERIOR SUBARU SVX 1992 Precaution for Supplemental Restraint System "Airbag" The Supplemental Restraint System "Airbag" helps to reduce the risk or severity of injury to the driver in a frontal collision The Supplemental Restraint System consists of an airbag module (located in the center of the steering wheel), sensors, a control unit, warning light, wiring harness and spiral cable Information necessary to service the safety is included in the "5-5 SUPPLEMENTAL RESTRAINT SYSTEM" of this Service Manual WARNING : To avoid rendering the Airbag system inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all maintenance must be performed by an authorized SUBARU dealer Improper maintenance, including incorrect removal and installation of the Airbag system, can lead to personal injury caused by unintentional activation of the Airbag system " All Airbag system electrical wiring harnesses and connectors are covered with yellow outer insulation Do not use electrical test equipment on any circuit related to the Supplemental Restraint System "Airbag" M MECHANISM AND FUNCTION Body Construction Cross-sectional Structure of Body Steering Support Beam Quietness Plastic and Resin-molded Outer Parts Painting Rust Prevention Sunroof Ventilation S SERVICE DATA Body Datum Points Datum Dimensions Datum Points and Dimensions Concerning On-Board Aiming Adjustment Rear Quarter Brace Welding C COMPONENT PARTS Body Construction Front Hood and Hood Lock Trunk Lid, Trunk Lid Opener, Fuel Flap and Fuel Flap Opener Front Bumper Rear Bumper Body Parts Outer Accessories Sunroof W SERVICE PROCEDURE Hood Trunk Lid (including trunk lid opener) Repair Instructions for Trunk Lid Fuel Flap (including fuel flap opener) " Front Bumper Rear Bumper Side Garnish Coating Method for PP Bumper and Side Garnish Repair Instructions for Colored PP Bumper and Side Garnish 10 Rear Quarter Garnish 11 Front Fender " 12 Mud Guard an ron Arch Protector ® 13 Cowl Panel Page 2 11 38 46 48 48 55 62 63 64 64 65 66 67 68 69 71 74 75 75 78 81 91 93 95 97 100 102 106 106 107 109 14 Front Grille 15 Under Cover 16 Side Splash Board 17 Ornament 18 Rear View Mirror 19 Sunroof T TROUBLESHOOTING Sunroof 110 110 110 110 111 111 116 116 5-1 Inn1oo1 BODY AND EXTERIOR M MECHANISM AND FUNCTION Body Construction The vehicle body is of monocoque construction with high rigidity 05-495 Fig BODY AND EXTERIOR (M2ool 5-1 Cross-sectional Structure of Body B-B D-D C-C A-A r E-E F-F I J-J Fig N-N H-H G-G / K-K M-M L \/ P-P R-R C5-496 BODY AND EXTERIOR 5-1 [M200] V" ` r~l~ o '44: ~p t > r I J High tensile strength steel sheet C5-497 Fig BODY AND EXTERIOR Steering Support Beam IM3001 5-1 also minimizes vibration and steering column extension in a collision A steering support beam is provided between the left and right front pillars to reinforce the steering column It C5-564 Fig BODY AND EXTERIOR 5-1 [Maoo1 Quietness A foam asphalt sheet provides a good contact surface with steel panels This increases the dampening effect 2) Silencers over the floor area Silencers minimize the transmission of noise/vibration into the passenger compartment An asphalt sheet covered with a resin layer is located on the floors in the spare tire stowage and front passenger seat, significantly reducing the transmission of noise and vibration 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 ) 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 Sandwitched steel sheet Resin layer Elastic and viscous layer A Asphalt sheet Floor panel %, , t4 ~lu~.R~.: , \ a< j l e-a \ / ~, Asphalt sheet covered with resin layer o Top board Steel panel `~ ' Foamed asphalt sheet /\ v\ ` , Asphalt sheet A-A C5-498 Fig Note: The asphalt sheet silencer without the resin layer is available as a replacement part to facilitate servicing BODY AND EXTERIOR 3) Sound-absorbing materials Insulators are installed in the engine hood, toe-board, IMaoo1 5-1 roof, lower front pillers, rear bulkhead, etc to increase the sound-absorbing effect C5-499 Fig 5-1 IM5001 BODY AND EXTERIOR Plastic and Resin-molded Outer Parts Trunk Lid (SMC) C J o ~~_~ r \~ y Y- Rear Bumper (Polypropylene) Rear Quarter Garnish (ABSresin) Side Garnish (Polypropylene) j Under Cover (Polypropylene) with glass fiber Front Bumper (Polypropylene) C5-500 Fig BODY AND EXTERIOR Painting [M6001 5-1 2) Metallic finish silver and peacock blue color Specification Color name Color code White Mica 167 Silver Metallic Black Mica 149 135 Dark Red Mica 165 Peacock Blue Metallic 169 Clear Color base Intermediate paint o, O " O" e o " oO tea oO o, Colored mica Paint film structure Paint film structure, after surfacing the steel sheet, is composed of electrocoated paint, intermediate paint and top coat paint Pigment C5-503 Fig 10 3) Mica finish .black and dark red color Top coat -~\ Intermediate paint Electrocoated paint Clear Steel sheet -~ Color base Intermediate paint ~.~.\~ ; ;~ `Aluminum pigment C5-501 Fig Pigment De pendin g on the finish color the followin g four kinds of paint are used for the top coat 1) Solid finish black color (roof) C5-504 Fig 11 ) M'Ica f'Irns ' h w h'rte co I or Clear Clear Color base Mica base Intermediate paint Color base Intermediate paint Pigment o ~° o °o ° Oo a o, Colored mica Pigment Fig C5-502 Fig 12 C5-505 5-1 [nns00] BODY AND EXTERIOR The color finish of the white mica paint is affected by the color of the base layer For convenience in checking the color during the body servicing, an area is provided where the mica base and clear layers are not applied ¢ (,yr ®~~ /jy' \~ f/ B r ; v / O % s Body side sill (right), upper side [Area: 55 x 130 mm (2 17 x5 12in)I l J Ye O C5-506 Fig 13 10 BODY AND EXTERIOR 5-1 [w9001 Repair Instructions for Colored PP Bumper and Side Garnish 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 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 MINOR DAMAGE CAUSING ONLY A CHANGE IN THE LUSTRE OF THE BUMPER DUE TO A LIGHT TOUCH Almost restorable Process No Cleaning Clean the area to be repaired using water Sanding Grind the repairing area with #500 sandpaper in a "feathering" motion Job contents Process name Finish Resin section Coated section Repeatedly apply wax to the affected area using a soft cloth (such as flannel) Recommended wax : NITTO KASEI Soft 99 TIRE WAX BLACK, or equivalent Polish the waxed area with a clean cloth after to 10 minutes Perform either the same operation as for the resin section or process No 18 and subsequent operations in the "(3)" section, depending on the degree and nature of damage DEEP DAMAGE CAUSED BY SCRATCHING FENCES, ETC A dent cannot be repaired but a whitened or swelled part can be removed Process No Job contents Process name Cleaning Clean damaged area with water Removal of damaged area Sanding Finish Cut off protruding area, if any, due to collision, using a putty knife Grind the affected area with #100 to #500 sandpaper Resin section Coated section Same as Process No in the "(1)" section 102 Perform Process No 12 and subsequent operations in the "(3)" section BODY AND EXTERIOR IW9031 5-1 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) Process No Process name Job contents Bumper removal Remove bumper as req uired Part removal Remove parts built into bumper as required Place bumper on a paint worktable as required It is recommended that contour of worktable accommodate internal shape of bumper Bumper Bumper Placement Set bumper section Fig 196 135-302 Surface preparation Remove dust, oil, etc from areas to be repaired and surrounding areas, using a suitable solvent (NRM No 900 Precleno, white gasoline, or alcohol) Cutting If nature of damage is cracks or holes, cut a guide slit of 20 to 30 mm (0.79 to 18 in) in length along the crack or hole up to the bumper's base surface Then, bevel or "vee ouC'the affected area using a knife or grinder L- J, 20 - 30 (0 79 - 18) Unit : mm (in) T 3(0 12) Paint surface PP base surface Sanding (I) Cleaning Fig 197 135-304 Grind beveled surface with sandpaper (#40 to #60) to smooth finish Clean the sanded surface with the same solvent as used in Process No Grind the side just opposite the beveled area with sandpaper (#40 to #60) and clean using a solvent Temporarily spot-weld the side, using a PP welding rod and heater gun Welded spot (Use heater gun and PP welding rod) Temporary welding PP base surface Beveled section Fig 198 a Do not melt welding rod until it flows out This results in reduced strength b Leave the welded spot unattended until it cools completely 103 135-305 5-1 IWS03) BODY AND EXTERIOR Process No Process name Job contents Using a heater gun and PP welding rod, weld the beveled spot while making the rod and damaged area Bumper Welding Set bumper section 135-302 Fig 199 Melt the sections indicated by hatched area Do not melt welding rod until it flows out, in order to provide strength Always keep the heater gun to cm 10.4 to in) away from the welding spot Leave the welded spot unattended until it cools completely 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 a b c d 10 Sanding (II) 135-307 Fig 200 Sand the welded spot smooth with #240 sandpaper 11 Masking Mask the black substrate section (as indicated in the figure), using masking tape Recommended masking tape : Nichiban No 533 or equivalent For details, see the figures showing the masking portions 12 Cleaning/degreasing Completely clean the entire coated area, using solvent similar to that used in Process No 13 Primer coating Apply a coat of primer to the repaired surface and its surrounding areas Mask these areas, if necessary Recommended primer : No 364 PP Primer Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5 to 3.5 kg/cm~ 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 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 ) 104 BODY AND EXTERIOR Process No Process name IW9031 5-1 Job contents 15 Primer surfacer coating Apply a coat of primer surfacer to the repaired area two or three times at an interval of to minutes Recommended surfacer : a UPS 300 Flex Primer e No 303 UPS 300 Exclusive hardener a NPS 725 Exclusive Reducer (thinner) e Mixing ratio : : (UPS 300 : No 303) e Viscosity : 12 - 14 sec/20°C (68°F) e Coated film thickness : 40 - 5011 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 sandpaper and water 18 Cleaning/degreasing 19 20 21 22 23 24 25 26 Top coat (1) Leave unattended Drying Top coat (II) Same as Process No 12 Solid color Metallic color Use a "block" coating method " Recommended paint : Suncryl (SC) No 307 Flex Hardener SC Reducer (thinner) Mixing ratio : : (Suncryl : No 307) Viscosity : 11 - 13 sec/20oC (68°F) Coated film thickness: 40 - 5011 Spraying thickness : 245 - 343 kPa (2 - kg/cm2, 36 - 50 psi) ""- "Coated film thickness : 20 - 3011 Not required Leave unattended at 20°C (68°F) for at least 10 minutes until the topcoated area is halfdry Be careful to keep dust or dirt from coming in contact with the affected area Not required Apply a clear coat three times at an interval of to minutes Recommended paint : SC710 Overlay Clear No 307 Flex Hardener SC Reducer (thinner) " Mixing ratio : : (SC710 : No 307) " Viscosity : 10 - 13 sec/20°C (68°F) " Coated film thickness : 20 - 3011 Spraying pressure : 245 - 343 kPa (2.5 - kg/cmZ, 36 - 50 psi) Allow the coated surface to dry at 20°C (68°F) for two hours or 60°C (140°F) for 30 minutes Do not allow the temperature to exceed 80° C (176° F) since this will deform the PP substrate Inspection Carefully check the condition of the repaired area Masking removal Remove masking tape applied in Process No 11 and 13 Parts installation Install parts on bumper in reverse order of removal Bumper installation Install bumper 105 5-1 [w10A0) BODY AND EXTERIOR 10 Rear Quarter Garnish 11 Front Fender Supplemental Restraint System "Airbag" A: REMOVAL Airbag system wiring harness is routed near the front fender a All Airbag system wiring harness and connectors are colored yellow Do not use electrical test equipment on these circuit b Be carefull not to damage Airbag system wiring harness when servicing the front fender 1) Remove clip at end of garnish A: REMOVAL Garnish Clip Body panel C5-177 Fig 201 1) 2) 3) 4) 5) Lift up the car Remove under cover Remove mud guard Remove front combination light Remove bolt securing fender to bumper side 2) Remove radio antenna holder (LH side only) Fig 204 C5-178 Fig 202 6) Remove stay from body panel 3) Remove clip by lifting front end of garnish Garnish Clip O Body ' Fig 203 Cs-r7s Fig 205 7) Remove front side garnish 8) Remove eleven attaching bolts B : INSTALLATION Installation is in the reverse order of removal 106 BODY AND EXTERIOR [W12A1] 5-1 12 Mud Guard and Front Arch Protector Supplemental Restraint System "Airbag" Airbag system wiring harness is routed near the mud guard and front arch protector a All Airbag system wiring harness and connectors are colored yellow Do not use electrical test equipment on these circuit b Be carefull not to damage Airbag system wiring harness when servicing the mud guard and front arch protector rig w0 9) Detach fender Be careful not to scratch body panels with fender edges when removing it B : INSTALLATION 1) Installation is in the reverse order of removal A: REMOVAL FRONT SIDE 1) Lift up the car after loosening wheel nuts 2) Remove tire 3) Remove under cover 4) Remove screw rivets, clips and screws 2) Check for alignment of front fender with hood and front door with front fender at all points Adjust, if necessary Fig 209 Fig 207 rig zu6 C5-215 C5-217 5) Detach mud guard 6) Remove bolt securing fender to bumper side rig zI u 7) Peel front end of front side garnish (refer to removal of front garnish ) 107 5-1 [w12A2] BODY AND EXTERIOR 6) Peel rear end of rear side garnish (refer to removal of rear side garnish), and then remove clip rig z I I 8) Remove screw and then detach arch protector REAR SIDE r1g L14 7) Detach arch protector 1) Lift up the car after loosening wheel nuts 2) Remove tire 3) Remove screw rivets and screws B: INSTALLATION Installation is in the reverse order of removal a Only use new nuts and clips b Ensure mud guard and arch protector are installed as shown in figure below Rear quarter panel Fender Fig 212 Mud guard R3 C5-220 4) Detach mud guard 5) Remove bolt securing rear quarter panel and bumper side, then remove clip Rear arch (INNER) panel `Mud guard Arch protector Front side Fig 215 r1g z73 108 Arch protector Rear side M223, BODY AND EXTERIOR 13 Cowl Panel (w 13B0) 5-1 5) Remove clips by lifting cowl panel A: REMOVAL ) Open front hood 91 Prv cline of opal nff usinn a flathprl screwririver- "V 61 Remove clios - - 3) Remove wiper arms 4) Remove side cowl panel to pry it off using a flatbed screwdriver Parfnrm this inh by clnsinn hnnd ,y 7) Rotate clip head 90°, and then detach cowl panel net - Fig 220 B: INSTALLATION Installation is in the reverse order of removal 109 c,5-22s 5-1 (W14A01 BODY AND EXTERIOR 14 Front Grille 16 Side Splash Board A: REMOVAL fA : REMOVAL While lightly pulling grille, pry clips off body using flatbed screwdriver 1) Lift up the car and remove wheel 2) Remove clip, nut and bolt Nut Clips Clip Body side Bolt Jl Peels o Press here to remove clip from body C5-229 Fig 221 B: INSTALLATION 1) Insert pawls of grill lower side into holes of body 2) Push clip into clip hole in body 15 Under Cover C5-231 Fig 223 F B_ INSTALLATION Installation is in the reverse order of removal 17 Ornament A: REMOVAL A: REMOVAL Cut double-sided adhesive tape using thin wire, and pull off ornament from clip Lift up the car and remove bolts Clip LL Clip Fig 222 B: INSTALLATION Installation is in the reverse order of removal `.Hood panel Adhesive tape C5-293 Fig 224 F B- INSTALLATION Install ornament after de-greasing ornament mounting surface on front hood 110 BODY AND EXTERIOR 18 Rear View Mirror [w19A1] 5-1 19 Sunroof A: REMOVAL FA- REMOVAL 1) Remove door trim and disconnect connector 1, 1) 2) by L SUNROOF PANEL Open sunroof approx 1/3 Remove clips attached to front side of sunroof trim Dullina trim from inside of compartment I ly «;.j 2) Remove weather-strip from around mirror mountinq y - 3) Move trim forward, and detach trim end from holder ,y «u 3) Remove bolts and detach mirror Fig 229 41 Detach trim B : INSTALLATION Installation is in the reverse order of removal Fig 230 111 C5-2461 5-1 [w19A2I BODY AND EXTERIOR 5) Close sunroof and remove nuts Fig 231 3) Remove relay by pulling it out C5-248 6) Remove sunroof panel Fig 234 SUNROOF FRAME SUNROOF MOTOR AND RELAY 1) Remove rear quarter trim, pillar trim, roof trim, etc (Refer to charter 5-3 ly 21 Disconnect connector and remove screws y -., , 1) Remove rear quarter trim, pillar trim, roof trim etc (Refer to chapter 5-3 ) 2) Remove sunroof panel 31 Disconnect drain tubes ,y 112 BODY AND EXTERIOR Iw19B2] 5-1 4) Disconnect connector between body harness and sun roof harness -~J / O t "' o 'o o o -moo Fig 237 0n CC (D I ly 'r *v C5-253 B: INSTALLATION 5) Loosen two mounting bolts near motor (Do not remove bolts.) SUNROOF PANEL, MOTOR AND RELAY Installation is in the reverse order of removal Sun roof trim reference pin must be fitted in holder notch SUNROOF FRAME 1) Insert frame rear end slit to two bolts fitted temporarilv to roof brace .ly e-00 6) Remove two bolts, eight nuts and four adjusting nuts ,y 21 Alion frame to reference Din installed on roof I& 7) Remove sunroof frame 8) Loosen set bracket mounting bolt y 113 5-1 [w19B2] BODY AND EXTERIOR 3) Tighten adjusting nut (that is, set frame at highest position) Flush Tnmn~rorihi +i~,F,fnn n+c ~nr1 L,.~I+c R1 Tinhfinn cnfi tir~n4nf mn~ ~nfiinn {~nl+c 71 Tinh+nn hnlfic nnrl mite 4) Install sunroof panel 5) Adjust height by turning adjusting nut Also adjust front, rear, right, and left-side partitions Partition clearance: 5.9± 0.5 mm (0.232± 0.020 in) Difference in height between roof panel and sunroof panel: 0± mm (0± 0.039 in) 8) Install drain tubes Insert drain tube securely up to bend of drain pipe 114 BODY AND EXTERIOR [W19B2] 5-1 11) Install sunroof trim, pillar trim, rear quarter trim etc 12) Check the following items after assembling all parts; " Garnish must be free from waves " When sun roof is fully closed, must be no clearance between garnish and sun roof trim " Sun roof must be free from slack and noise when it is fully opened and closed Fig 248 9) Install roof trim 10) Install garnish Place garnish joint at rear center of body Center n Rear Fig 249 JI / r- J Front C5-26 115 BODY AND EXTERIOR 5-1 IT1oo1 T TROUBLESHOOTING Sunroof Entry of water into compartment t Check sunroof panel and roof panel for improper clearance Check sunroof trim and roof trim for improper clearance Booming noise Abnormal motor noise Failure of sunroof to operate (Motor operates properly) Motor does not rotate or rotates improperly (Use sunroof wrench to check operation ) Check roof panel and sunroof panel for improper or poor sealing Check drain tube for clogging Check sunroof frame seal and body for improper fit Check Check Check Check Check Check Check Check Check Check motor for looseness gears and bearings for wear cable for wear cable pipe for deformities guide rail for foreign particles guide rail for improper installation parts for mutual interference cable slider for improper clinching cable for improper installation clutch adjustment nut for improper tightness Check fuse for blowout Check switch for improper function Check motor for incorrect terminal voltage Check relay for improper operation Check poor grounding system Check cords for discontinuity and terminals for poor connections Check limit switch for improper operation 116 ...5-1 Inn1oo1 BODY AND EXTERIOR M MECHANISM AND FUNCTION Body Construction The vehicle body is of monocoque construction with high rigidity 05-495 Fig BODY AND EXTERIOR (M2ool 5-1 Cross-sectional... frames Sec B C5- 524- 5 Sec C C5- 524- 6 Side frame (UPR) Front and rear side frame (UPR) End of flange Front wheel apron Front side frame (front) n Sec D C5- 524- 7 24 IM7071 BODY AND EXTERIOR 5-1 Unit... Remarks - 5-1 IM7071 BODY AND EXTERIOR Hot Wax Application C5-523 Fig 29 22 BODY AND EXTERIOR No Cross sectional view Applied section : IM7071 5-1 Thickness Remarks Rear and front end section