1999 SUBARU LEGACY Service Repair Manual

Process
No.Process name Job contents
5 CuttingIf nature of damage are cracks or holes,
cut a guide slit of 20 to 30 mm (0.79 to
1.18 in) in length along the crack or hole
up to the bumper's base surface. Then,
bevel or ªvee- outº 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.
8 Temporary weldingGrind the side just opposite the beveled area with sand paper (#40 to #60) and clean
using a solvent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.
G5M0166
NOTE:
IDo not melt welding rod until it flows out. This results in reduced strength.
ILeave the welded spot unattended until it cools completely.
9 WeldingUsing a heater gun and PP welding rod, weld the beveled spot while melting the rod
and damaged area.
G5M0167
NOTE:
IMelt the sections indicated by hatched area.
IDo not melt welding rod until it flows out, in order to provide strength.
IAlways keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
ILeave the welded spot unattended until it cools completely.
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7. Repair Instructions for Colored PP Bumper

Process
No.Process name Job contents
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/ degreasingCompletely 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 necessary.
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 20ÉC (68ÉF) 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.)
15 Primer surfacer coatingApply a coat of primer surfacer to the repaired area two or three times at an interval of
3 to 5 minutes.
Recommended surfacer:
IUPS 300 Flex primer
INo. 303 UPS 300 Exclusive hardener
INPS 725 Exclusive reducer (thinner)
IMixing ratio:2:1(UPS 300: No. 303)
IViscosity: 12 Ð 14 sec/20ÉC (68ÉF)
ICoated film thickness: 40 Ð 50
16 DryingAllow the coated surface to dry for 60 minutes at 20ÉC (68ÉF) [or 30 minutes at 60ÉC
(140ÉF)].
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 coatSolid color Metallic color
Use a ªblockº coating method.
IRecommended paint:
Suncryl (SC)
No. 307 Flex hardener
SC reducer (thinner)
IMixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex hardener
IViscosity: 11 Ð 13 sec/20ÉC (68ÉF)
ICoated film thickness: 40 Ð 50
ISpraying thickness: 245 Ð 343 kPa
(2.5 Ð 3.5 kg/cm
2, 36 Ð 50 psi)Use a ªblockº coating method.
IRecommended paint:
Suncryl (SC)
No. 307 Flex hardener
SC Reducer (thinner)
IMixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex Hardener
IViscosity: 11 Ð 13 sec/20ÉC (68ÉF)
ICoated film thickness: 20 Ð 30
ISpraying thickness: 245 Ð 343 kPa
(2.5 Ð 3.5 kg/cm2, 36 Ð 50 psi)
20 Leave unattended. Not required.Leave unattended at 20ÉC (68ÉF) for at
least 10 minutes until the top coated area
is half-dry.
NOTE:
Be careful to keep dust or dirt from com-
ing in contact with the affected area.
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7. Repair Instructions for Colored PP Bumper

Process
No.Process name Job contents
21 Top coat (II) Not required.Apply a clear coat three times at an inter-
val of 3 to 5 minutes.
IRecommended paint:
Suncryl (SC)
No. 307 Flex hardener
SC Reducer (thinner)
IMixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex Hardener
IViscosity: 11 Ð 13 sec/20ÉC (68ÉF)
ICoated film thickness: 20 Ð 30
ISpraying thickness: 245 Ð 343 kPa
(2.5 Ð 3.5 kg/cm
2, 36 Ð 50 psi)
22 DryingAllow the coated surface to dry at 20ÉC (68ÉF) for two hours or 60ÉC (140ÉF) for 30
minutes.
NOTE:
Do not allow the temperature to exceed 80ÉC (176ÉF) 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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7. Repair Instructions for Colored PP Bumper

8. Front Fender
A: REMOVAL AND INSTALLATION
1) Disconnect ground cable from battery.
2) Remove bracket which secures mud guard to
front fender.
B5M0285A
3) Remove mud guard.
NOTE:
Do not remove the entire mud guard, only the front
section of it.
4) Remove headlight.
5) Remove bolts which secure front fender.
Remove front fender.
B5M0286
6) Installation is in the reverse order of removal.
NOTE:
Check for alignment of front fender with hood and
front door with front fender at all points. Adjust, if
necessary.
G5M0175
B5M0287A
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8. Front Fender

9. Mud Guard and Rear Arch
Protector
A: REMOVAL AND INSTALLATION
1. MUD GUARD (EXCEPT OUTBACK
MODEL)
1) Jack-up vehicle to remove tire.
2) Remove screws and clips. Move mud guard
toward the center of the body and remove mud
guard.
B5M0288
3) Installation is in the reverse order of removal.
CAUTION:
Only use new screws and clips.
2. MUD GUARD (OUTBACK MODEL)
1) Jack-up vehicle to remove tire.
2) Remove screws and clips. Move mud guard
toward the center of the body and remove mud
guard.
B5M0410
3) Installation is in the reverse order of removal.
CAUTION:
Only use new screws and clips.
3. REAR ARCH PROTECTOR
1) Remove rear arch protector.
B5M0289
2) Installation is in the reverse order of removal.
CAUTION:
Only use new screws and clips.
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9. Mud Guard and Rear Arch Protector

10. Cowl Panel
A: REMOVAL AND INSTALLATION
1) Remove wiper arms.
2) Open front hood.
3) Remove cowl panel seal using a plier.
B5M0290A
4) Lift cowl panel and detach it from clips attached
to body panel.
B5M0291
5) Installation is in the reverse order of removal.
NOTE:
When installing cowl panel, first attach a middle
clip to the cap attached to body panel. Then tap the
cowl panel to attach it to other clips.
11. Molding and Retainer
A: REMOVAL AND INSTALLATION
1) Remove weatherstrip.
2) Remove tapping screws.
B5M0292
3) Installation is in the reverse order of removal.
NOTE:
Insert molding and retainer onto hook, then fasten
with screws.Insert molding and retainer onto hook,
then fasten with screws.
B5M0293A
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10. Cowl Panel

10. Cowl Panel
A: REMOVAL AND INSTALLATION
1) Remove wiper arms.
2) Open front hood.
3) Remove cowl panel seal using a plier.
B5M0290A
4) Lift cowl panel and detach it from clips attached
to body panel.
B5M0291
5) Installation is in the reverse order of removal.
NOTE:
When installing cowl panel, first attach a middle
clip to the cap attached to body panel. Then tap the
cowl panel to attach it to other clips.
11. Molding and Retainer
A: REMOVAL AND INSTALLATION
1) Remove weatherstrip.
2) Remove tapping screws.
B5M0292
3) Installation is in the reverse order of removal.
NOTE:
Insert molding and retainer onto hook, then fasten
with screws.Insert molding and retainer onto hook,
then fasten with screws.
B5M0293A
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10. Cowl Panel

12. Front Grille
A: REMOVAL AND INSTALLATION
1) Remove four upper clips from body panel. To
facilitate removal, press portion shown in figure
using screwdriver.
B5M0294A
2) Pull front grille to detach it from two lower clips.
(Two lower clips remain on headlight.)
3) Installation is in the reverse order of removal.
NOTE:
Attach all clips to grille. Align them with clip hole in
body and push them into place.
13. Door Mirror
A: REMOVAL AND INSTALLATION
1) Remove the gusset cover.
B6M0146
2) Remove inner remote control switch cover.
B5M0296
3) Remove front door trim.
B5M0297
4) Remove front door trim.
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13. Door Mirror