Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Legacy 1995-1999 Approved Subaru Legacy 1996 1996 Service Manual BODY SECTION BODY AND EXTERIOR MSA5TCD96L6290

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SERVICE PROCEDURE 5-1
7. Repair Instructions for Colored PP Bumper

7. 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 lustre of the base material
or coating, can be almost fully restored. Before repairing a
damaged area, explain this point to the customer and get
an understanding about the matter.
Repair methods are outlined below, based on a classifica-
tion of the extent of damage.

1. MINOR DAMAGE CAUSING ONLY A CHANGE IN
THE LUSTRE OF THE BUMPER DUE TO A LIGHT
TOUCH
It is almost restorable as follows:
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). Perform either the same operation as for the
3 Finish Recommended wax: NITTO KASEI Soft 99 TIRE resin section or process No. 18 and subsequent
WAX BLACK, or equivalent. operations in the "3." section, depending on the
Polish the waxed area with a clean cloth after 5 degree and nature of damage.
to 10 minutes.

2. 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 opera-
Same as process No. 3 in the "1." section.
tions in the "3." section.

47
5-1 SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper

3. 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 Job contents
No.
1 Bumper removal Remove bumper as required.
2 Parts removal Remove parts built into bumper as required.

Place bumper on a paint work table as required.
3 Bumper placement It is recommended that contour of work table
accommodates internal shape of bumper.

G5M0164

Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
4 Surface preparation
(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
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 sol-
vent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.

8 Temporary welding

G5M0166

NOTE:

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