1996 SUBARU LEGACY service interval

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.
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5-1SERVICE PROCEDURE
6. Coating Method for PP Bumper

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

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 Flex hardener
SC reducer (thinner)

Mixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex hardener

Viscosity: 11—13 sec/20°C (68°F)

Coated film thickness: 40—50µ

Spraying thickness: 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)

Mixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex Hardener

Viscosity: 11—13 sec/20°C (68°F)

Coated film thickness: 20—30µ

Spraying thickness: 245—343 kPa
(2.5—3.5 kg/cm2,36—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)

Mixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex hardener

Viscosity: 10—13 sec/20°C (68°F)

Coated film thickness: 20—30µ

Spraying pressure: 245—343 kPa
(2.5—3.5 kg/cm
2,36—50 psi)
22 DryingAllow the coated surface to dry at 20°C (68°F) for two hours or 60°C (140°F) for 30 minutes.
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 Masking removal Remove masking tape applied in process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
26 Bumper installation Install bumper.
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5-1SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper

C: FUNCTION TEST
1. SECURITY SYSTEM OPERATION
1) Fully open all the door windows.
2) Turn the ignition switch to OFF and remove ignition key
from ignition switch.
3) Get out of the vehicle and lock the driver’s door using a
ignition key.
4) Check that the security indicator light illuminates.
5) When the security indicator light illuminates, wait for 30
seconds.
After 30 seconds, check that the light starts repeating 0.2
sec. ON and 2.4 sec. OFF sequence.
6) Unlock the driver’s door using the inside lock knob and
open the door.
Ensure that:
(1) the horn sounds and headlights flash intermittently
at 0.2 sec. ON and 0.6 sec. OFF. intervals, and
(2) the engine will not start even if the ignition switch
is turned to START.
7) Unlock the driver’s door one time using the ignition key.
Ensure the horn and headlights turn off.
8) Close and lock the driver’s door without using a ignition
key. (Set the inside lock knob to LOCK and then close the
door while lifting the outer handle).
Check that the security indicator light illuminates continu-
ously.
9) Within 30 seconds after the above step 8), unlock the
rear LH door using the inside lock knob and open the door.
Check that the security indicator light flashes at 0.5 sec.
intervals.
10) Close the rear LH door and lock the door using the
inside lock knob.
Check that the security indicator light illuminates continu-
ously.
11) Perform the above steps 9) and 10) on the rear RH
door and front RH door.
12) Within 30 seconds after above step 11) has been
finished, pull the engine hood opener lever and open the
engine hood.
Check that the security indicator light flashes at 0.5 sec.
intervals.
13) Close the engine hood completely.
Check that the security indicator light illuminates continu-
ously.
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6-2SERVICE PROCEDURE
22. Security System

14) Within 30 seconds after the above step 13), pull the
trunk lid opener lever and open the trunk lid (SEDAN); or
unlock the rear gate by operating the driver’s door inside
lock knob and open the rear gate (WAGON).
Check that the security indicator light flashes at 0.5 sec.
intervals.
15) Close the trunk lid completely (SEDAN); or close the
rear gate and lock by locking the driver’s door using a igni-
tion key (WAGON).
Check that the security indicator light illuminates continu-
ously.
16) When the security indicator light illuminates
continuously, wait for 30 seconds.
After 30 seconds, check that the light starts repeating 0.2
sec. ON and 2.4 sec. OFF sequence.
17) Unlock the trunk lid (SEDAN) or rear gate (WAGON)
using a ignition key and open.
Check that the horn and headlights do not operate.
18) Close the trunk lid (SEDAN) or rear gate (WAGON).
19) Unlock and then lock the driver’s door using a ignition
key and wait for 30 seconds.
After 30 seconds, check that the light starts repeating 0.2
sec. ON and 2.4 sec. OFF sequence.
20) Only WAGON model; unlock and then lock the rear
gate using a ignition key and wait for 30 seconds.
After 30 seconds, check that the light starts repeating 0.2
sec. ON and 2.4 sec. OFF sequence.
21) Unlock the front RH door using a ignition key and open
the door.
Check that the horn and headlights do not operate.
After finishing the above checks, ensure that security sys-
tem’s function is correct.
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6-2SERVICE PROCEDURE
22. Security System