Subaru 2009 IMPREZA Service Manual page 3199

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)
Process
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 the damage is a crack or a hole, 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. Next, use a knife or grinder to carve a
V-shaped groove in the area for repair.
Grind the beveled surface with sand paper (#40 — #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 — #60) and clean using a
solvent.
Temporarily spot-weld the side, using 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.
EI-33
EXTERIOR/INTERIOR TRIM
Job contents
(1)
(2)
(1) Bumper
(2) Set bumper section
(3)
(4)
(1) Paint surface
(2) PP base surface
(3) 20 — 30 mm (0.79 — 1.18 in)
(4) 3 mm (0.12 in)
(1)
(2)
(3)
EI-00234
(1)
(2)
EI-00235
EI-00236