Subaru Legacy IV (2008 year). Manual - part 1133

EI-31

Front Bumper

EXTERIOR/INTERIOR TRIM

2. FRONT BUMPER BEAM ASSEMBLY

1) Disconnect the ground cable from the battery.
2) Remove the front bumper face. <Ref. to EI-30,
FRONT BUMPER FACE, REMOVAL, Front
Bumper.>
3) Remove the energy absorber foam from bumper
beam.
4) Remove the headlight assembly. <Ref. to LI-13,
REMOVAL, Headlight Assembly.>
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, and disassemble the
bumper beam.

7) Remove the under cover.
8) Remove the bolts and clips, and remove the ra-
diator guide.

B: INSTALLATION

1. FRONT BUMPER FACE

1) Install in the reverse order of removal.
2) Fit the bumper face to the gap (B) between the
guide bracket (A) and fender securely.

3) Replace the double-sided tape with new one,
and install it to the side garnish.

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-01724

EI-01023

EI-00578

EI-01725

(A)

(B)

EI-32

Front Bumper

EXTERIOR/INTERIOR TRIM

C: REPAIR

1. COATING METHOD FOR PP BUMPER

Process 

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 if possible.

(1) Bumper
(2) Set bumper section

2

Masking

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

3

Degreasing/cleaning

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

4

Primer paint

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

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
• Mixture ratio:
Main agent : 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 kg/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
• Mixture ratio:
Main agent : 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 kg/cm

2

, 36 — 50 psi)

7

Drying

Not required.

Dry at normal temperature [at least 10 min. at 
20°C (68°F)].
In half-dried condition, avoid dust, dirt.

8

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 to be used:
Metallic paint
Hardener PB
Thinner T-301
• Mixture ratio:
Clear coat : 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 kg/cm

2

, 36 — 50 psi)

9

Drying

60°C (140°F), 60 min. or 80°C (176°F), 30 min.
If higher than 80°C (176°F), PP may become be deformed. Keep maximum temperature 80°C 
(176°F) or less.

10

Inspection

Check paint.

11

Removal of masking

Remove the masking tape applied in procedure 2.

EI-00234

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(1)

EI-33

Front Bumper

EXTERIOR/INTERIOR TRIM

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. Damages limited to the shallow scratches that cause only a change in the luster
of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this
point to the customer and obtain an understanding about the matter. Repair methods are outlined below,
based on a classification of the extent of damage.
1) Minor damage causing only a change in the luster of the bumper due to a light touch
Almost restorable.

2) Deep damage caused by scratching with fences etc.
A dent cannot be repaired but a whitened or swelled part can be removed.

Process 

No.

Process name

Job contents

1

Cleaning

Clean the area to be repaired using water.

2

Sanding

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

3

Finish

Resin section

Coated section

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

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

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

Process 

No.

Process name

Job contents

1

Cleaning

Clean the damaged area with water.

2

Removal of dam-
aged area

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

3

Sanding

Sand the affected area with #100 — #500 sand paper.

4

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.

EI-34

Front Bumper

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)

Process 

No.

Process name

Job contents

1

Bumper removal

Remove the bumper as required.

2

Removal of parts

Remove the parts built into bumper as required.

3

Bumper placement

Place the bumper on a paint worktable as 
required.
It is recommended to use the paint worktable 
conforming to internal shape of bumper.

(1) Bumper
(2) Set bumper section

4

Surface preparation

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.).

5

Cutting

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.

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

6

Sanding (I)

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

7

Cleaning

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

8

Temporary welding

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-00234

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(1)

EI-00235

(4)

(2)

(1)

(3)

EI-00236

(1)

(2)

(3)