Subaru Legacy 2002 Service Manual page 3072

¼ 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
Process name
No.
1 Bumper removal
2 Part removal
3 Bumper placement
4 Surface preparation
5 Cutting
6 Sanding (I)
7 Cleaning
8 Temporary welding
FRONT BUMPER
Remove bumper as required.
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.
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable sol-
vent (NRM No. 900 Precleno, white gasoline, or alcohol).
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.
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
solvent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.
NOTE:
¼ Do not melt welding rod until it flows out. This results in reduced strength.
¼ Leave the welded spot unattended until it cools completely.
EI-17
Job contents
Exterior/Interior Trim
G5M0164
G5M0165
G5M0166