Subaru Legacy IV (2008 year). Service manual - part 1134

EI-35

Front Bumper

EXTERIOR/INTERIOR TRIM

9

Welding

Using a heater gun and PP welding rod, weld the beveled spot while melting both the rod and 
damaged area.

(1) Welding rod
(2) Melt hatched area
(3) Section

NOTE:
• Melt the sections indicated by hatched area.
• Do not melt the welding rod until it flows out, in order to provide strength.
• Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
• Leave the welded spot unattended until it cools completely.

10

Sanding (II)

Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife, 
operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will 
cause the PP substrate to melt from the heat.

Sand the welded spot smooth with #240 sand paper.

11

Masking

Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent

12

Cleaning/degreas-
ing

Completely clean the entire coated area, using solvent similar to that used in procedure No. 4.

13

Primer coating

Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if 
necessary.
Recommended primer: Mp/ 364 PP Primer

NOTE:
Be sure to apply a coat of primer using a spray gun at a pressure of 245 — 343 kPa (2.5 — 3.5 kg/cm

2

,

36 — 50 psi).

14

Leave unattended

Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-dry.

NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampened with alcohol. 
(Do not use thinner since the coated area tends to melt.)

15

Primer surfacer 
coating

Apply primer surfacer to the repaired area two or three times at an interval of 3 — 5 minutes.
• Recommended surfacer:
UPS 300 Flex Primer
No. 303 UPS 300 Exclusive hardener
NPS 725 Exclusive Reducer (thinner)
• Mixture ratio:
2 : 1 (UPS 300 : No. 303)
• Viscosity: 12 — 14 seconds/20°C (68°F)
• Coating film thickness: 40 — 50 μ

16

Drying

Allow the coated surface to dry for 20 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].

Process 

No.

Process name

Job contents

(1)

(2)

(2)

(3)

EI-00237

EI-00042

EI-36

Front Bumper

EXTERIOR/INTERIOR TRIM

17

Sanding (III)

Sand the coated surface and its surrounding areas using #400 sand paper and water.

18

Cleaning/degreasing Same as process No. 12.

19

Top coat (I)

Non-colored

Metallic paint

Use a “block” coating method.
• Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
• Mixture ratio:
Suncryl (SC): No. 307 Flex Hardener = 3 : 1
• Viscosity: 11 — 13 seconds/20°C (68°F)
• Coating film thickness: 40 — 50 μ
• Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

Use a “block” coating method.
• Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
• Mixture ratio:
Suncryl (SC): No. 307 Flex Hardener = 3 : 1
• Viscosity: 11 — 13 seconds/20°C (68°F)
• Coating film thickness: 20 — 30 μ
• Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

20

Leave unattended

Not required

Leave unattended at 20°C (68°F) for at least 
10 minutes until the top coated area is half-dry.

NOTE:
Be careful to keep dust or dirt from coming in 
contact with the affected area.

21

Top coat (II)

Not required

Apply a clear coat three times at an interval of 
3 to 5 minutes.
• Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
• Mixture ratio:
Suncryl (SC): No. 307 Flex Hardener = 3 : 1
• Viscosity: 10 — 13 seconds/20°C (68°F)
• Coating film thickness: 20 — 30 μ
• Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm

2

, 36 — 50 psi)

22

Drying

Allow the coated surface to dry for two hours at 20°C (68°F) or 30 minutes at 60°C (140°F).

NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP substrate.

23

Inspection

Carefully check the condition of the repaired area.

24

Removal of masking Remove the masking tape applied in process No. 11 and 13.

25

Parts installation

Install parts on the bumper in reverse order of removal.

26

Bumper installation

Install the bumper.

Process 

No.

Process name

Job contents

EI-37

Rear Bumper

EXTERIOR/INTERIOR TRIM

9. Rear Bumper

A: REMOVAL

1. REAR BUMPER FACE (SEDAN MODEL)

1) Turn over the mud guard, and remove the bolt
(A) inside wheel house, and the clips (B) on the
lower side of the bumper.

2) Remove the clips on the lower side of rear bumper.

3) Remove the service hole cover, and remove the
bolt.

4) Remove the bumper face from vehicle body in
the order from (a) to (e).

(1) Detach the engaged section from the corner
bracket of the rear combination light RH and
LH.
(2) Detach the engaged section of the bumper
face center from one end to the another.

NOTE:
Do not pull with an excessive force. Otherwise the
bumper face flange sections may be damaged.

2. REAR BUMPER FACE (WAGON MODEL)

1) Disconnect the ground cable from the battery.
2) Remove the rear combination light assembly.
<Ref. to LI-23, REMOVAL, Rear Combination Light
Assembly.>
3) Remove the two clips.

4) For OUTBACK model, remove the rear fender
side garnish.

NOTE:
To remove the side garnish claw (A) from the
bumper face.
5) Turn over the mud guard, and remove the bolt
(A) inside wheel house, and the clips (B) on the
lower side of the bumper.

EI-00580

(A)

(B)

EI-00581

EI-00583

EI-01582

(c)

(d)

(e)

(a)

(b)

EI-00579

EI-01727

(A)

EI-00580

(A)

(B)

EI-38

Rear Bumper

EXTERIOR/INTERIOR TRIM

6) Remove the clips on the lower side of rear
bumper.

7) Remove the service hole cover, and remove the
bolt.

NOTE:
For models with woofers, remove the woofer cover.

8) Remove the rear bumper from vehicle body.

NOTE:
• Do not pull with a excessive force. Otherwise the
bracket installation area may be damaged.
• To facilitate the removal of bracket, detach the
engaged sections between bumper face and brack-
et from one end to the other.

3. REAR BUMPER BRACKET

Remove the rear bumper face from vehicle body,
and remove each bumper bracket.
• Corner bracket

• Sedan model

• Wagon model

• Lower bracket

• Sedan model

• Wagon model

EI-00581

EI-00584

EI-00585

EI-01058

(1)

(2)

(3)

EI-01583

EI-00587

EI-00641

EI-00588