Subaru Legacy (2005 year). Manual - part 993

EI-29

EXTERIOR/INTERIOR TRIM

Mud Guard

7. Mud Guard

A: REMOVAL

1. FRONT MUD GUARD

1) Jack-up the vehicle. 
2) Remove the front wheels. 
3) Loosen the screws and clips to remove mud
guard. 

2. REAR MUD GUARD

1) Jack-up the vehicle. 
2) Remove the rear wheels. 
3) Loosen the screws and clips to remove mud
guard. 

B: INSTALLATION

1. FRONT MUD GUARD

Install in the reverse order of removal. 

2. REAR MUD GUARD

Install in the reverse order of removal. 

EI-00639

EI-00640

EI-30

EXTERIOR/INTERIOR TRIM

Front Bumper

8. Front Bumper

A: REMOVAL

1. FRONT BUMPER FACE

1) Disconnect the ground cable from battery. 
2) Remove the front grille. <Ref. to EI-24, REMOV-
AL, Front Grille.>
3) Turn over the front mud guard, and remove the
clip connecting fender with bumper. 

4) Remove the clips at the lower side of bumper. 

5) Disconnect the fog light connector. (Model with
fog light)
6) Remove the bumper from vehicle body. 
7) Remove the fog light from bumper face. <Ref. to
LI-21, REMOVAL, Front Fog Light Assembly.>

2. FRONT BUMPER BEAM ASSEMBLY

1) Disconnect the ground cable from battery. 
2) Remove the front grille. <Ref. to EI-24, REMOV-
AL, Front Grille.>

3) Remove the front bumper face. <Ref. to EI-30,
FRONT BUMPER FACE, REMOVAL, Front
Bumper.>
4) Remove the energy absorber foam from bumper
beam. 

5) Remove the bolts, and remove the bumper
beam assembly from vehicle body. 

NOTE:
After all bolts are removed, raise the whole bumper
beam a little to remove it from vehicle body. 
6) Remove the bolts and nuts to disassemble
bumper beam. 

EI-00572

EI-00573

EI-00575

EI-00576

EI-00577

EI-31

EXTERIOR/INTERIOR TRIM

Front Bumper

7) Remove the clips, and remove the radiator
guide. 

8) Remove the bolts and clips, and remove the
bumper lower center bracket. 

B: INSTALLATION

1. FRONT BUMPER FACE

1) Install in the reverse order of removal. 
2) Fit the slider (A) to the guide plate (B) securely. 

2. FRONT BUMPER BEAM ASSEMBLY

Install in the reverse order of removal. 

Tightening torque:

Refer to “COMPONENT” of “General Descrip-
tion”. <Ref. to EI-5, FRONT BUMPER, COM-
PONENT, General Description.>

EI-00801

EI-00578

EI-00571

(B)

(A)

EI-32

EXTERIOR/INTERIOR TRIM

Front Bumper

C: REPAIR

1. COATING METHOD FOR PP BUMPER

Pro-

cess 

No. 

Process name

Job contents

1

Bumper installation

Place the bumper on a paint worktable as 
required. Use the paint worktable conforming to 
inner shape of bumper when possible. 

(1) Bumper
(2) Bumper cross-section view

2

Masking

Mask specified part (black base) with masking tape. Use masking tape for PP (example: Nichiban 
No. 533, etc.).

3

Degreasing, clean-
ing

Clean all parts to be painted with white gasoline, ordinary alcohol, etc. to remove dirt, oil, fat, etc. 

4

Primer paint

Apply primer to all parts to be painted, using spray gun. Use primer (non-color). 

5

Drying

Dry at normal temperature [10 — 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)

Non-colored

Metallic paint

Use section (block) paint for top coat. 
• Paint to be used (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 — 45 

µ

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kgf/cm

2

, 36 — 50 psi)

Use section (block) paint for top coat. 
• Paint to be used (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 — 20 

µ

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kgf/cm

2

, 36 — 50 psi)

7

Drying

Not required. 

Dry at normal temperature [more than 10 min. 
at 20

°C (68°F)]. 

In half-dried condition, avoid dust, dirt. 

8

Top coat paint (II)

Not required. 

Apply clear coat to the parts with top coat paint 
(I), three times at 5 — 7 minutes interval. 
• Paint to be used:
Metallic paint
Hardener PB
Thinner T-301
• Mixing ratio:
Clear coat vs. hardener = 6:1
• Viscosity: 14 — 16 sec. /20

°C (68°F)

• Film thickness: 25 — 30 

µ

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kgf/cm

2

, 36 — 50 psi)

9

Drying

60 min. at 60

°C (140°F), or 30 min. at 80°C (176°F)

If higher than 80

°C (176°F), PP may be deformed. Keep maximum temperature at 80°C (176°F). 

10

Inspection

Paint check. 

11

Masking removal

Remove masking tape applied in process No. 2. 

EI-00234

(2)

(1)