1996 SUBARU LEGACY Service Repair Manual

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Page 1473 of 2890

SUBARU LEGACY 1996 Service Repair Manual B5M0282
5) Remove rear bumper assembly.
B5M0283A
B5M0284A
B5M0380A
B: INSTALLATION
1. EXCEPT OUTBACK WITH STEP ROOF
To install the rear bumper, reverse the above removal pro-
cedures.
CAUTION:
Be ext

Page 1474 of 2890

SUBARU LEGACY 1996 Service Repair Manual B5M0283A
B5M0284A
2. OUTBACK WITH STEP ROOF
To install the rear bumper, reverse the above removal pro-
cedures.
CAUTION:
Be extremely careful to prevent scratches on
bumper face as it is made of resi

Page 1475 of 2890

SUBARU LEGACY 1996 Service Repair Manual 6. Coating Method for PP Bumper
1. PROCESS STEPS
Process
No.Process name Job contents
1 Bumper mountingSet bumper on paint work table if required. Use
paint work table conforming to inner shape of
bum

6. Coating Method for PP Bumper
1. PROCESS STEPS
Process
No.Process name Job contents
1 Bumper mountingSet bumper on paint work table if required. Use
paint work table conforming to inner shape of
bumper when possible.
G5M0164
2 MaskingMask specified part (black base) with masking tape. Use masking tape for PP (e.g., Nichiban No.
533, etc.).
3Degreasing, clean-
ingClean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
4 Primer paint First, apply one coat of primer to all parts to be painted, using air gun. Use primer (clear).
5 DryingDry at normal temperature [10 to 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)Solid color Metallic color
Use section (block) paint for top coat.
Paint in use (for each color):
Solid paint
Hardener PB
Thinner T-301
Mixing ratio:
Main agent vs. hardener = 4:1
Viscosity: 10—13 sec/20°C (68°F)
Film thickness: 35—45µ
Spraying pressure: 245—343 kPa
(2.5—3.5 kg/cm
2,36—50 psi)Use section (block) paint for top coat.
Paint in use (for each color):
Metallic paint
Hardener PB
Thinner T-306
Mixing ratio:
Main agent vs. hardener = 10:1
Viscosity: 10—13 sec/20°C (68°F)
Film thickness: 15—20µ
Spraying pressure: 245—343 kPa
(2.5—3.5 kg/cm2,36—50 psi)
7 Drying Not required.Dry at normal temperature [10 min. or more 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 in use:
Metallic paint
Hardener PB
Thinner T-301
Mixing ratio: Clear vs. hardener = 6:1
Viscosity: 14—16 sec/20°C (68°F)
Film thickness: 25—30µ
Spraying pressure: 245—343 kPa
(2.5—3.5 kg/cm
2,36—50 psi)
9 Drying60°C (140°F), 60 min. or 80°C (176°F), 30 min.
If higher than 80°C (176°F), PP may be deformed. Keep maximum temperature of 80°C (176°F).
10 Inspection Paint check
11 Masking removal Remove masking in process No. 2.
46
5-1SERVICE PROCEDURE
6. Coating Method for PP Bumper

Page 1476 of 2890

SUBARU LEGACY 1996 Service Repair Manual 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 t

Page 1477 of 2890

SUBARU LEGACY 1996 Service Repair Manual 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 s

Page 1478 of 2890

SUBARU LEGACY 1996 Service Repair Manual Process
No.Process name Job contents
9 WeldingUsing a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged
area.
G5M0167
NOTE:
Melt the sections indicated by hatched

Process
No.Process name Job contents
9 WeldingUsing a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged
area.
G5M0167
NOTE:
Melt the sections indicated by hatched area.
Do not melt 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.
G5M0168
Sand the welded spot smooth with #240 sand paper.
11 MaskingMask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12 Cleaning/degreasing Completely clean the entire coated area, using solvent similar to that used in process No. 4.
13 Primer coatingApply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if neces-
sary.
Recommended primer: Mp/ 364 PP primer
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5 to 3.5 kg/cm
2,36
to 50 psi) with a spray gun.
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 dampended with alcohol.
(Do not use thinner since the coated area tends to melt.)
15Primer surfacer
coatingApply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 min-
utes.
Recommended surfacer:UPS 300 Flex primer
No. 303 UPS 300 Exclusive hardener
NPS 725 Exclusive reducer (thinner)
Mixing ratio:2:1(UPS 300: No. 303)
Viscosity: 12—14 sec/20°C (68°F)
Coated film thickness: 40—50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
49
5-1SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper

Page 1479 of 2890

SUBARU LEGACY 1996 Service Repair Manual Process
No.Process name Job contents
18 Cleaning/degreasing Same as process No. 12.
19 Top coat (I)Solid color Metallic color
Use a“block”coating method.
Recommended paint:
Suncryl (SC)
No. 307 F

Page 1480 of 2890

SUBARU LEGACY 1996 Service Repair Manual 8. Front Fender
A: REMOVAL
SUPPLEMENTAL RESTRAINT SYSTEM“AIRBAG”
Airbag system wiring harness is routed near the front
fender.
CAUTION:
All Airbag system wiring harness and connectors
are colored

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