Subaru Legacy III (2000-2003 year). Manual - part 978

EI-14

EXTERIOR/INTERIOR TRIM

FRONT BUMPER

4. Front Bumper

A: REMOVAL

1) Open hood.
2) Disconnect ground cable from battery.
3) Pull off front side of front mud guard, then re-
move bolts from inside the mud gruand.

4) Remove clip at bottom of bumper.

5) Remove clip (A), and pull out bumper slightly.
6) Disconnect electrical connector of fog light to re-
move bumper.

7) Remove bumper beam.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

Refer to COMPONENT in General Descrip-
tion. <Ref. to EI-2, FRONT BUMPER, COM-
PONENT, General Description.>

EI-00127

EI-00128

EI-00129

( A )

EI-00131

EI-15

EXTERIOR/INTERIOR TRIM

FRONT BUMPER

C: REPAIR

1. COATING METHOD FOR PP BUMPER

Pro-

cess

No.

Process name

Job contents

Bumper mounting

Set bumper (A) on paint worktable (B) if
required. Use paint worktable conforming to
inner shape of bumper when possible.

Masking

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

Degreasing, clean-
ing

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

Primer paint

Apply primer one to all parts to be painted, using air gun. Use primer (clear).

Drying

Dry 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.

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

• Film thickness: 35 — 45

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kg/cm

, 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

• Film thickness: 15 — 20

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kg/cm

, 36 — 50 psi)

Drying

Not required.

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

C (68

F)].

In half-dried condition, avoid dust, dirt.

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

• Film thickness: 25 — 30

• Spraying pressure: 245 — 343 kPa

(2.5 — 3.5 kg/cm

, 36 — 50 psi)

Drying

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).

Inspection

Paint check.

Masking removal

Remove masking in process No. 2.

EI-00132

( A )

( B )

EI-16

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-
stored 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.

• Deep damage caused by scratching fences, etc.

A dent cannot be repaired but a whitened or swelled part can be removed.

• 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)

Pro-

cess

No.

Process name

Job contents

Cleaning

Clean the area to be repaired using water.

Sanding

Grind the repairing area with #500 sand paper in a “feathering” motion.

Finish

Resin section

Coated section

Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recom-
mended wax: NITTO KASEI Soft 99 TIRE WAX
BLACK, or equivalent.

Perform either the same operation as for the
resin section or process No. 18 and subse-
quent operations in the “(3)” section, depending
on the degree and nature of damage.

Polish the waxed area with a clean cloth after 5
to 10 minutes.

Pro-

cess

No.

Process name

Job contents

Cleaning

Clean damaged area with water.

Removal of dam-
aged area

Cut off protruding area, if any, due to collision, using a putty knife.

Sanding

Grind the affected area with #100 to #500 sand paper.

Finish

Resin section

Coated section

Same as Process No. 3 in the “(1)” section.

Perform Process No. 12 and subsequent oper-
ations in the “(3)” section.

Pro-

cess

No.

Process name

Job contents

Bumper removal

Remove bumper as required.

Part removal

Remove parts built into bumper as required.

Bumper placement

Place bumper (A) on a paint worktable (B) as
required.
It is recommended that contour of worktable
accommodate internal shape of bumper.

EI-00132

( A )

( B )

EI-17

EXTERIOR/INTERIOR TRIM

FRONT BUMPER

Surface prepara-
tion

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 are cracks or holes, cut a
guide slit of 20 to 30 mm (0.79 to 1.18 in) in
length along the crack or hole up to the
bumper's base surface. Then, bevel or “vee-
out” the affected area using a knife or grinder.

(1) Paint surface
(2) PP base surfave
(3) 20 — 30 mm (0.79 — 1.18 in)
(4) 3 mm (0.12 in)

Sanding (I)

Grind beveled surface with sand paper (#40 to #60) to smooth finish.

Cleaning

Clean the sanded surface with the same solvent as used in Process No. 4.

Temporary welding

Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a sol-
vent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.

(1) Welded spot (Use heater gun and PP welding rod)
(2) PP base surface
(3) Beveled section
NOTE:
• Do not melt welding rod until it flows out. This results in reduced strength.
• Leave the welded spot unattended until it cools completely.

Welding

Using 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
NOTE:
• 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 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
• Leave the welded spot unattended until it cools completely.

Pro-

cess

No.

Process name

Job contents

EI-00294

( 1 )

( 2 )

( 3 )

( 4 )

EI-00135

( 1 )

( 2 )

( 3 )

EI-00136

( 1 )

( 2 )

( 3 )

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