1999 SUBARU LEGACY Service Repair Manual

3. Fuel Flap
A: REMOVAL AND INSTALLATION
1. FUEL FLAP
1) Remove bolts which hold hinge to fuel flap, and
detach fuel flap.
B5M0373
2) Installation is in the reverse order of removal.
CAUTION:
Make sure the clearance between fuel flap and
vehicle body is equal at all points.
2. FUEL FLAP OPENER
1) Remove rear seats, center pillar lower cover,
floor mat, rear arch cover/rear quarter trim
(Wagon), and side sill cover (on the driver's side).
2) Remove all clips which hold cable.
3) Disconnect cable from pull handle.
B5M0374A
4) Detach pull handle by removing bolts.
5) Detach fuel lock holder by turning it.
6) Installation is in the reverse order of removal.
CAUTION:
IWhen installing cover to pull handle
assembly, observe the following:
IBe careful not to catch harness.
IEngage pull handle assembly pawls
firmly.
IAfter installing opener cable, ensure it
moves smoothly.
4. Front Bumper
A: REMOVAL AND INSTALLATION
1. EXCEPT OUTBACK MODEL
1) Disconnect the ground cable from the battery.
2) Remove two bolts from lower center of bumper.
B5M0273
3) Remove mud guard.
NOTE:
It is not necessary to remove the entire mud guard.
Remove clips from the front section of mud guard,
if necessary.
4) Remove the canister.
5) Remove two bolts from side of bumper.
B5M0274
6) Remove front grill.
7) Remove headlight.
8) Remove clips from both sides of front bumper.
NOTE:
When removing, push the pin at the center of clip
with a thin screwdriver.
B5M0376
41
[W4A1]5-1SERVICE PROCEDURE
4. Front Bumper

9) Remove bolts (engine compartment side) from
bumper stays.
B5M0275
10) Remove front bumper assembly.
NOTE:
Front bumper surface is accessible for removal
after removing the following parts:
Two bolts (on the lower center of bumper), mud
guard, bolts (on the side of bumper), front grille,
headlight, clips (on both sides of front bumper),
clips (on the upper section of bumper), and clips
(on the lower section of bumper).
B5M0276
11) Installation is in the reverse order of removal.CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing the bumper.
IWhen installing canister, insert air vent hose
of canister into the hole on body.
ITo facilitate installation of front bumper,
insert the protrusion inside bumper into the
groove of body.
B5M0375A
2. OUTBACK MODEL
1) Disconnect the ground cable from the battery.
G6M0095
2) Remove two bolts from lower center of bumper.
B5M0273
3) Remove mud guard.
NOTE:
It is not necessary to remove the entire mud guard.
Remove clips from the front section of mud guard,
if necessary.
4) Remove the canister.
42
5-1[W4A2]SERVICE PROCEDURE
4. Front Bumper

5) Remove two bolts from side of bumper.
B5M0274
6) Remove front grill.
7) Remove headlight.
8) Remove fog lamps.
9) Remove clips from both sides of front bumper.
NOTE:
When removing, push the pin at the center of clip
with a thin screwdriver.
B5M0376
10) Remove bolts (engine compartment side) from
bumper stays.
B5M0275
11) Remove front bumper assembly.
NOTE:
Front bumper surface is accessible for removal
after removing the following parts:
Two bolts (on the lower center of bumper), mud
guard, bolts (on the side of bumper), front grille,
headlight, clips (on both sides of front bumper),
clips (on the upper section of bumper), and clips
(on the lower section of bumper).
B5M0406
12) Installation is in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing the bumper.
IWhen installing canister, insert air vent hose
of canister into the hole on body.
ITo facilitate installation of front bumper,
insert the protrusion inside bumper into the
groove of body.
B5M0375A
43
[W4A2]5-1SERVICE PROCEDURE
4. Front Bumper

5. Rear Bumper
A: REMOVAL AND INSTALLATION
1. SEDAN
1) Remove one bolt and one clip from side of
bumper.
B5M0377
2) Open trunk lid. Remove trunk trim panel clips
and detach trim.
3) Remove rear bumper beam (upper) attaching
nut.
4) Remove bolts from bumper stays.
B5M0378
5) Remove rear bumper assembly.
B5M0280
6) Installation is in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.ITo facilitate installation of rear bumper,
attach slider to the guide pin.
B5M0283A
B5M0284A
ITo facilitate installation of rear bumper,
insert the bumper hook into the body groove.
B5M0380A
2. WAGON
1) Remove one bolt and one clip from side of
bumper.
B5M0377
2) Open rear gate. Remove rear quarter trim lid.
44
5-1[W5A1]SERVICE PROCEDURE
5. Rear Bumper

3) Remove two clips from lower center of bumper.
B5M0379
4) Remove bolts from bumper stays.
B5M0281
5) Remove rear bumper assembly.
B5M0282
6) Installation is in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.ITo facilitate installation of rear bumper,
attach slider to the guide pin.
B5M0283A
B5M0284A
ITo facilitate installation of rear bumper,
insert the bumper hook into the body groove.
B5M0380A
3. OUTBACK MODEL
1) Remove one clip from side of bumper.
B5M0407
2) Open rear gate and remove rear quarter trim
lid.
45
[W5A3]5-1SERVICE PROCEDURE
5. Rear Bumper

3) Remove five bolts from lower center of bumper.
B5M0408
4) Remove bolts from bumper stays.
B5M0409
5) Remove rear bumper assembly.
B5M0282
6) Installation is in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.ITo facilitate installation of rear bumper,
attach slider to the guide pin.
B5M0283A
B5M0284A
ITo facilitate installation of rear bumper,
insert the bumper hook into the body groove.
B5M0380A
46
5-1[W5A3]SERVICE PROCEDURE
5. Rear Bumper

6. Coating Method for PP Bumper
A: 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.).
3 Degreasing, cleaningClean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt,
oil, fat, etc.
4 Primer paintFirst, 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 20ÉC (68ÉF)].
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.
IPaint in use (for each color):
Solid paint
Hardener PB
Thinner T-301
IMixing ratio:
Main agent vs. hardener = 4:1
IViscosity: 10 Ð 13 sec/20ÉC (68ÉF)
IFilm thickness: 35 Ð 45
ISpraying pressure: 245 Ð 343 kPa (2.5
Ð 3.5 kg/cm
2, 36 Ð 50 psi)Use section (block) paint for top coat.
IPaint in use (for each color):
Metallic paint
Hardener PB
Thinner T-306
IMixing ratio:
Main agent vs. hardener = 10:1
IViscosity: 10 Ð 13 sec/20ÉC (68ÉF)
IFilm thickness: 15 Ð 20
ISpraying pressure: 245 Ð 343 kPa (2.5
Ð 3.5 kg/cm2, 36 Ð 50 psi)
7 Drying Not required.Dry at normal temperature [10 min. or
more at 20ÉC (68ÉF)].
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, at5Ð7minutes
intervals.
IPaint in use:
Metallic paint
Hardener PB
Thinner T-301
IMixing ratio: Clear vs. hardener = 6:1
IViscosity: 14 Ð 16 sec/20ÉC (68ÉF)
IFilm thickness: 25 Ð 30
ISpraying pressure: 245 Ð 343 kPa (2.5
Ð 3.5 kg/cm
2, 36 Ð 50 psi)
9 Drying60ÉC (140ÉF), 60 min. or 80ÉC (176ÉF), 30 min.
If higher than 80ÉC (176ÉF), PP may be deformed. Keep maximum temperature of
80ÉC (176ÉF).
10 Inspection Paint check
11 Masking removal Remove masking in process No. 2.
47
[W6A0]5-1SERVICE PROCEDURE
6. Coating Method for 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 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 get an understanding about the matter.
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
It is almost restorable as follows:
Process
No.Process name Job contents
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sand paper in a ªfeatheringº motion.
3 FinishResin section Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel).
Recommended wax: NITTO KASEI Soft
99 TIRE WAX BLACK, or equivalent.Perform either the same operation as for
the resin section or process No. 18 and
subsequent operations in the ª3.º section,
depending on the degree and nature of
damage. Polish the waxed area with a
clean cloth after 5 to 10 minutes. Polish the waxed area with a clean cloth
after 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
No.Process name Job contents
1 Cleaning Clean damaged area with water.
2Removal of damaged
areaCut off protruding area, if any, due to collision, using a putty knife.
3 Sanding Grind the affected area with #100 to #500 sand paper.
4 FinishResin section Coated section
Same as process No. 3 in the ª1.º section.Perform process No. 12 and subsequent
operations in the ª3.º section.
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 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
No.Process name Job contents
1 Bumper removal Remove bumper as required.
2 Parts removal Place bumper on a paint work table as required.
3 Bumper placementPlace bumper on a paint work table as
required. It is recommended that contour
of work table accommodates internal
shape of bumper.
G5M0164
4 Surface preparationRemove dust, oil, etc. from areas to be repaired and surrounding areas, using a suit-
able solvent (NRM No. 900 precleno, white gasoline, or alcohol).
48
5-1[W700]SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper