Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 1999-2000 BODY AND ELECTRICAL SECTION Body and Exterior MSA5T0126A27872

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MSA5T0126A27872


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5-1   [W600]                            SERVICE           PROCEDURE
6. Repair Instructions for Colored PP Bumper


6. Repair Instructions for Colored PP Bumper
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be
restored to its former condition. Damage limited to shallow scratches that cause only a change in the lus-
tre of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain
this point to the customer and obtain his or her understanding. Repair methods are outlined below, based
on a classification of the extent of damage.

A: MINOR DAMAGE CAUSING ONLY A CHANGE IN THE LUSTRE OF THE
BUMPER DUE TO A LIGHT TOUCH
Almost restorable.
 Process
           Process name                                                Job contents
   No.
    1    Cleaning          Clean the area to be repaired using water.
    2    Sanding           Grind the repairing area with #500 sand paper     in a "feathering" motion.
                                             Resin section                                     Coated section
                           Repeatedly apply wax to the affected area
                           using a soft cloth (such as flannel). Recom-        Perform either the same operation as for the
    3    Finish            mended wax: NITTO KASEI Soft 99 TIRE                resin section or process No. 18 and subse-
                           WAX BLACK, or equivalent.                           quent operations in the "(3)" section, depend-
                           Polish the waxed area with a clean cloth after      ing on the degree and nature of damage.
                           5 to 10 minutes.

B: DEEP DAMAGE CAUSED BY SCRATCHING FENCES, ETC.
A dent cannot be repaired but a whitened or swelled part can be removed.
 Process
           Process name                                                Job contents
   No.
    1    Cleaning          Clean damaged area with water.
         Removal of dam-
    2                      Cut off protruding area, if any, due to collision, using a putty knife.
         aged area
    3    Sanding           Grind the affected area with #100 to #500 sand paper.
                                            Resin section                                 Coated section
    4    Finish                                                           Perform Process No. 12 and subsequent
                           Same as Process No. 3 in the "(1)" section.
                                                                          operations in the "(3)" section.




                                                           34
                                         SERVICE PROCEDURE                                                 [W6C0] 5-1
                                                                           6. Repair Instructions for Colored PP Bumper


C: 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 may not
be worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
 Process
           Process name                                                Job contents
   No.
    1    Bumper removal     Remove bumper as required.
    2    Part removal       Remove parts built into bumper as required.



                            Place bumper on a paint worktable as
         Bumper place-      required.
    3
         ment               It is recommended that contour of worktable
                            accommodate internal shape of bumper.


                                                                                                                   G5M0164
         Surface prepara-   Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable sol-
    4
         tion               vent (NRM No. 900 Precleno, white gasoline, or alcohol).




                            If damage includes cracks or holes, cut a
                            guide slit of 20 to 30 mm (0.79 to 1.18 in) in
    5    Cutting            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.



                                                                                                                   G5M0165
    6    Sanding (I)        Grind beveled surface with sand paper (#40 to #60) to smooth finish.
    7    Cleaning           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.




         Temporary weld-
    8
         ing




                                                                                                                   G5M0166
                            NOTE:
                            



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