Subaru Legacy 2005 Service Manual page 3986

EXTERIOR/INTERIOR TRIM
3) Deep damage such as a break or hole that requires filling
Much of the peripheral grained surface must be sacrificed for repair. 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 Process name
No.
1 Bumper removal
2 Removal of parts
3 Bumper placement
Surface prepara-
4
tion
5 Cutting
6 Sanding (I)
7 Cleaning
8 Temporary welding
Front Bumper
Remove the bumper as required.
Remove the parts built into bumper as required.
Place the bumper on a paint worktable as
required.
It is recommended to use the paint worktable
conforming to internal shape of bumper.
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol, etc.)
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
base surface. Then, bevel or "vee-out" the
affected area using a knife or grinder.
Grind beveled surface with sand paper (#40 to #60) to smooth finish.
Clean the sanded surface with the same solvent as used in Process No. 4.
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 point (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.
Job contents
(1)
(1) Bumper
(2) Bumper cross-section view
(4)
(1) Paint surface
(2) PP base surface
(3) 20 — 30 mm (0.79 — 1.18 in)
(4) 3 mm (0.12 in)
(1)
(3)
EI-34
(2)
(3)
(1)
(2)
(2)
EI-00234
EI-00235
EI-00236