MSA5TCD95S 24 body and exterior

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 . ...... . . . . .. ..... . . . . ... . . . . . .. . . . . .
1 . Body Construction .... . . .. ... . . . . . ...... . . . . .. ..... . . . . ... . . . . . .... . . .
2. Cross-sectional Structure of Body . ..... . . . . ... . . . . . .... . . .
3. Steering Support Beam .. .. . . . ...... . . . . . ...... . . .. ... .. . . . .... . . .
4. Quietness

..... . ...... . . . . ... . . . . ..... . . . ........ . . . . .. . . . . . . . . .... . . . .... . . .

5. Plastic and Resin-molded Outer Parts . . . . ..... . . . .... . . .
6. Painting . . . . ..... . .. .... . . . . ... . . . . ..... . . . ........ . . . . ..... . . . . .. ... . . . .... . . .
7. Rust Prevention .. . . . . .... . . . ..... . . . .. ...... . . . . .. ... . . . . ..... . . . .... . . .
8. Sunroof . . . . ..... . . . .... . . . . .... . . . ..... . . . ........ . . . . ..... . . . . . . ... . . . .... . . .
9 . Ventilation . .. . . . . .. .. .. . . .... . . . . . ..... . . . ........ . . . . .... . . . . . ... . . . . . .... .
S SERVICE DATA .. . . . ...... . . . .. . . . . . . ..... . . . . ....... . . . . .... . . . . . ... . . . ...... .
1 . Body Datum Points .... . . . . . ... .. . . . ........ . . . . .... . . . . . ... . . . .... .. .
2. Datum Dimensions .... . . . . . ... .. . . . ........ . . . . .... . . . . . ... . . . .... . . .
3. Datum Points and Dimensions Concerning
On-Board Aiming Adjustment ...... . . . . .... . . . . . ... . . . ..... . .
4 Rear Quarter Brace Welding . ........ . . . . .... . . . . . ... . . . .... . . .
C COMPONENT PARTS . . . ... . . . . . ..... . . . ........ . . . . .... . . . . . ... . . . .... .. .
1 . Body Construction . . ... .. . . . .. ... .. . . . ...... . . . . . ... . . . . . ..... . ...... .
2. Front Hood and Hood Lock . . . . ...... . . . . . ... . . . . . ..... . ...... .
3. Trunk Lid, Trunk Lid Opener, Fuel Flap and
Fuel Flap Opener .. . . . ..... . . . . . ... . . . . . ...... . . . . . ... . . . . . ..... . ...... .
4. Front Bumper . . . . .... . . . ..... . . . .. ... . . . . . ...... . . . . .... . . . . . ..... . ...... .
5. Rear Bumper . . . . . .... . . . ..... . . . ..... . . . . . ...... . . . . .... . . . . . ..... . ...... .
6 . Body Parts . . .... . . . ...... . . .... . . . . . ..... . . . .. .... .. . . . ... . . . . . ..... . . . .. . . .
7 . Outer Accessories .. . ..... . . . . . ..... . . . .. .... .. . . . ... . . . . . .. ... . . . .... .
8 . Sunroof ... . . . . .. .. . . . ...... . . .... . . . . . ..... . . . .. .... . . . . . ... . . . . . . . . .. . . . .... .

W SERVICE PROCEDURE . .... . . . . . ..... . . . .. .... .. . . . ... . . . . . .. ... . . . .... .
1 . Hood . . . ..... . . . .... . . . ...... . . .... . . . . . ..... . . . .. .... .. . . . ... . . . . . . . ... . . . .... .
2 . Trunk Lid (including trunk lid opener) . . . . . . . .... . . . .... .
3 . Repair Instructions for Trunk Lid ... . . . ... .. . . . . . ... . . . .... .
4. Fuel Flap (including fuel flap opener) .... . . . . . ... . . . .... .
" .
5 . Front Bumper
. . . . . ... . . . . . . .... . . . . ... . . . . . . . ... . . . .... .
6 . Rear Bumper .. . . . . . .... . . .... . . . . . . . ... . . . . . .... . . . . . ... . . . . . . . ... . . . .... .
7 . Side Garnish .. . . . . . .... . . .... . . . . . .. ... . . . . . .... . . . . . ... . . . . . . .... . . . .... .
8. Coating Method for PP Bumper and Side
Garnish . .... . . . ..... . . . ...... ...... . . . . . .... . . . . ...... . . . ..... . . . .. ... . ...... .
9 . 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
2
3
5

6

8
9
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 . .... . . ...... . . . . . ... . . . . . ...... . . ...... . . . ..... . . . ...
1 . Sunroof . . . .... . . . ... . . . . . .... . . .... .. . . . . . ... . . . . . ... . .. . . ..... . . . . . . ... . . . ...

110
110
110
110
111
111
116
116


5-1 Inn1oo1

BODY AND EXTERIOR

M MECHANISM AND FUNCTION

1 . Body Construction

The vehicle body is of monocoque construction with high rigidity .

05-495

Fig . 1

2


BODY AND EXTERIOR

(M2ool 5-1

2. Cross-sectional Structure of Body

B-B

D-D

C-C

A-A

r
E-E

F-F

I

J-J

Fig . 2

N-N

H-H

G-G

/
K-K

M-M

L

\/
P-P

R-R

3

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. 3

4


BODY AND EXTERIOR

3 . 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. 4

5


BODY AND EXTERIOR

5-1 [Maoo1

4. 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 .
1 ) 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 7

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. 5
Note: The asphalt sheet silencer without the resin layer is available as a replacement part to facilitate servicing .

6


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. 6

7


5-1 IM5001

BODY AND EXTERIOR

5 . 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. 7

8


BODY AND EXTERIOR

6 . 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 . 8

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
4 ) 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

0
a o, .

Colored mica
Pigment

Fig . 9

C5-502

Fig . 12

9

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

7 . Rust Prevention

IM706j 5-1

4. Sealer and Adhesive Application

The following items are utilized where necessary to
protect the body against corrosion .

1 . Panel Arrangement

rig. I

5. Polyvinyl Chloride (PVC) Application
(Uses new material .)

C5-507

Fig. 14
2. Galvanized Sheet Metal Application

Fig . 18

6. Anti Chipping Coat (ACC) Application
(Uses new material .)

rig. / a

3 . Cation Electrocoating

Fig . 16

rig. 1-4

C5-509

11

C5-511



BODY AND EXTERIOR

5-1 [nn7oo1

M MECHANISM AND FUNCTION

7. Rust Prevention
8. Rustproof Parts

Fig . 1
No.

Applied section

Anti-rust material

1

Rubber
(arch protector)
Polyethylene

(mud guard)

i `p

8

Fen d er

Mud guard
Archr protector
C5-526-1

2

Remarks
-


BODY AND EXTERIOR
No .

Applied section

[Wool 5-1
Anti-rust material

2

Rubber
(arch protector)

,~

Remarks
-

Polyethylene
(mud guard)

Rear quarter panel
Rear arch
M (inner) panel
Mud guard

( ®av

Arch protector

C5-526-2
3

Polyethylene

-

Polypropylene

-

with glass fiber

. 'j

"

, h

c,

V~L
"`"

x

\I

`

'-C

C5-526-3
4

C5-526-8


BODY AND EXTERIOR

5-1 [M7001

Applied section

No .

Anti-rust material

5

I

I

Remarks

Polypropylene

-

Multi-layer
plastic

-

d

J d
V 'J

d

d

C5-526-9
6

\

I

/`I

I /

rte,//~

C5-526-6


[M7ooi 5-1

BODY AND EXTERIOR
Applied section

No .

Anti-rust material

7

Nylon
(Plug)
Polypropylene (Hot

melting plug)

c~

.,

~~o

M

C

I1

U

C5-526-7

Fig. 2

Remarks
-



BODY AND EXTERIOR

[M701] 5-1

1 . Panel Arrangement

Members are installed on the passenger compartment
side of the floor panels to prevent rust formation on the
lapped portions .

J~

SEC. A Transmission cross member
locating portion

j

SEC. C Center bearing locating portion

7 ~--

--ner

SEC . B Muffler hanger
locating portion

SEC. D Front seat locating portion

C5-516

Fig . 23

13

5-1

[M7021

BODY AND EXTERIOR

2. Galvanized Sheet Metal Application

Galvanized sheet metal is used for all body sheet metal
parts.

~~

`gay ~~%o

40.
lkko

P

4

Fig. 24

~

C5-517

Galvanized both side

14


[M704]

BODY AND EXTERIOR

5-1

4. Sealer and Adhesive Application
2O Front hood

®Hood hinge
t-© Fuel flap
1

i

O Engine compartment

\

y
%
Door

127 Under floor ~/

O Door hinge

C5-518

Pa_ 25
Anti-rust material

Applied section

No .
1

Sealer

o
-f

Qo
o

0 ; I

e 0

.'tJ
t.
y

f~

0
L.y

:\

Y

(

L

L
L

C5-519-1

15

Remarks
-


5-1

[M704]

BODY AND EXTERIOR

No .

Applied section

Anti-rust material
Sealer

2
A

Remarks
-

lA~
`-~J~ l\
l j
00 ~

0

1

O

\~

0

o

O

Adhesive
Anti-rust type adhesive

\40~
Sec . A

C5-519-2
3

Sealer

i
O

o

O OD °
~o

-

I

B

Adhesive
Anti-rust type adhesive

Sec. B

C5-519-3
4

Sealer
i

i

\~\

1

C5-519-4

16

-


BODY AND EXTERIOR
Applied section

No .
5

IM7oa1 5-1
Anti-rust material

Remarks

Sealer

-

Sealer

-

o
dPP

C5-519-5
6

C

0

Anti-rust type adhesive
Sec. C

7

\

~

Adhesive

C5-519-6

\

Sealer

o

O

o

\~

o 0

o

C5-519-7

17

-


5-1

IM7o51

BODY AND EXTERIOR

5. Polyvinyl Chloride (PVC) Application
(Uses new material .)

Thickness

400 microns:

300 microns:
100 microns:

C5-520

Fig . 26

18


BODY AND EXTERIOR
No .

Cross sectional view

1

[M705)

Applied section

Thickness

Remarks

Front wheel house

Over 400 microns

-

Rear wheel house

Over 400 microns

-

Toe-board

00ver 300 microns

-

`-Front wheel apron

Sec. A

Sec. B

C5-521-1
2 I

r

J

~J

\ \1

L

Sec. C

C5-521-2

3
n

.~ U

I

~i

1 ~

,

2t~'

S
`Y

J.

x1

\

-fS

<

C5-521-3

19

5-1


5-1

IM7051

BODY AND EXTERIOR

No.

Cross sectional view

Applied section

4

Thickness

Remarks

Front floor

Over 300 microns
* : Over 400
microns

-

Rear floor pan
(front)

Carer 100 microns

-

Rear floor pan
(rear)

Over 300 microns
* : Over 400
microns

-

Side rear floor

Carer 300 microns
* : Over 400
microns

-

Rear suspension
bracket

Over 400 microns

-

Sec. D
C5-521-4
5
\~

~ \ \\

_--

`-'

\V

C5-521-5
6

Sec. F

Sec. E

C5-521-6

7
i

Sec . G

C5-521-7

8

Sec. H
C5-521-8

20