SUBARU LEGACY 1995 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 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

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 yellow. Do not use electrical test equip-
ment on these circuits.

Be careful not to damage Airbag system wiring har-
ness when servicing the front fender.
B5M0285A
1) Disconnect ground cable from battery.
2) Remove bracket which secures mud guard to front
fender.
3) Remove mud guard.
NOTE:
Do not remove the entire mud guard, only the front section
of it.
4) Remove headlight.
B5M0286
5) Remove bolts which secure front fender.
Remove front fender.
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5-1SERVICE PROCEDURE
8. Front Fender

G5M0175
B: INSTALLATION
1) Installation is in the reverse order of removal.
2) Check for alignment of front fender with hood and front
door with front fender at all points. Adjust, if necessary.
B5M0287A
9. Mud Guard and Rear Arch
Protector
A: REMOVAL
SUPPLEMENTAL RESTRAINT SYSTEM“AIRBAG”
Airbag system wiring harness is routed near the mud
guard.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuits.

Be careful not to damage Airbag system wiring har-
ness when servicing the mud guard.
B5M0288
1. MUD GUARD
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.
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5-1SERVICE PROCEDURE
8. Front Fender - 9. Mud Guard and Rear Arch Protector

G5M0175
B: INSTALLATION
1) Installation is in the reverse order of removal.
2) Check for alignment of front fender with hood and front
door with front fender at all points. Adjust, if necessary.
B5M0287A
9. Mud Guard and Rear Arch
Protector
A: REMOVAL
SUPPLEMENTAL RESTRAINT SYSTEM“AIRBAG”
Airbag system wiring harness is routed near the mud
guard.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuits.

Be careful not to damage Airbag system wiring har-
ness when servicing the mud guard.
B5M0288
1. MUD GUARD
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.
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5-1SERVICE PROCEDURE
8. Front Fender - 9. Mud Guard and Rear Arch Protector

B5M0289
2. REAR ARCH PROTECTOR
Remove rear arch protector.
B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Only use new screws and clips.
B5M0290A
10. Cowl Panel
A: REMOVAL
1) Remove wiper arms.
2) Open front hood.
3) Remove cowl panel seal using a plier.
B5M0291
4) Lift cowl panel and detach it from clips attached to body
panel.
B: INSTALLATION
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.
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5-1SERVICE PROCEDURE
9. Mud Guard and Rear Arch Protector - 10. Cowl Panel

B5M0289
2. REAR ARCH PROTECTOR
Remove rear arch protector.
B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Only use new screws and clips.
B5M0290A
10. Cowl Panel
A: REMOVAL
1) Remove wiper arms.
2) Open front hood.
3) Remove cowl panel seal using a plier.
B5M0291
4) Lift cowl panel and detach it from clips attached to body
panel.
B: INSTALLATION
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.
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5-1SERVICE PROCEDURE
9. Mud Guard and Rear Arch Protector - 10. Cowl Panel

B5M0292
11. Molding and Retainer
A: REMOVAL
1) Remove weatherstrip.
2) Remove tapping screws.
B5M0293A
B: INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Insert molding and retainer onto hook, then fasten with
screws.
B5M0294A
12. Front Grille
A: REMOVAL
1) Remove four upper clips from body panel. To facilitate
removal, press portion shown in figure using screwdriver.
2) Pull front grille to detach it from two lower clips.
(Two lower clips remain on headlight.)
B: INSTALLATION
Attach all clips to grille. Align them with clip hole in body
and push them into place.
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5-1SERVICE PROCEDURE
11. Molding and Retainer - 12. Front Grille

B5M0292
11. Molding and Retainer
A: REMOVAL
1) Remove weatherstrip.
2) Remove tapping screws.
B5M0293A
B: INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Insert molding and retainer onto hook, then fasten with
screws.
B5M0294A
12. Front Grille
A: REMOVAL
1) Remove four upper clips from body panel. To facilitate
removal, press portion shown in figure using screwdriver.
2) Pull front grille to detach it from two lower clips.
(Two lower clips remain on headlight.)
B: INSTALLATION
Attach all clips to grille. Align them with clip hole in body
and push them into place.
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11. Molding and Retainer - 12. Front Grille

B6M0146
13. Door Mirror
A: REMOVAL
1) Remove the gusset cover.
B5M0296
2) Remove inner remote control switch cover.
B5M0297
3) Remove inner remote control switch.
4) Remove front door trim.
B5M0298A
5) Disconnect the door mirror connector.
6) Remove the door mirror installation screws.
B: INSTALLATION
Installation is in the reverse order of removal.
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5-1SERVICE PROCEDURE
13. Door Mirror

B5M0381A
14. Side Protector
A: REMOVAL
Side protector consists of three parts; front fender, front
door and rear door.
B5M0285A
1. SIDE PROTECTOR FRONT FENDER PORTION
1) Remove bracket which secures mud guard to front
fender.
2) Remove mud guard.
NOTE:
Detach the rear part of mud guard as required for the pro-
cedure. It is not necessary to remove the entire mud guard.
3) Use pliers to remove a clip from inside front fender.
Remove it from vehicle body but keep it with side protec-
tor.
2. SIDE PROTECTOR FRONT DOOR AND REAR
DOOR PORTIONS
1) Remove trim panel.
2) Use pliers to remove clips from inside of doors. Remove
them from vehicle body but keep them with side protector.
NOTE:
Front door portion has five clips, rear door portion has four
clips.
B: INSTALLATION
Installation is in the reverse order of removal.
NOTE:
To install side protector front door and rear door portions,
insert the first clip into the base hole [9 mm (0.35 in) dia.],
and then insert other clips.
CAUTION:
Insert clips firmly and carefully by hand. To avoid dam-
aging clips, do not forcefully push or hit clips.
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5-1SERVICE PROCEDURE
14. Side Protector