SUBARU LEGACY 1997 Service Repair Manual

2. OUTBACK WITH STEP ROOF
To install the front bumper, reverse the above removal pro-
cedures.
CAUTION:

Be extremely careful to prevent scratches on
bumper face as it is made of resin.

Be careful not to scratch the body when removing or
installing the bumper.

When installing canister, insert air vent hose of can-
ister into the hole on body.
B5M0377
5. Rear Bumper
A: REMOVAL
1. SEDAN
1) Remove one bolt and one clip from side of bumper.
2) Open trunk lid. Remove trunk trim panel clips and
detach trim.
B5M0378
3) Remove rear bumper beam (upper) attaching nut.
4) Remove bolts from bumper stays.
B5M0280
5) Remove rear bumper assembly.
B5M0377
2. WAGON
1) Remove one bolt and one clip from side of bumper.
2) Open rear gate. Remove rear quarter trim lid.
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5-1SERVICE PROCEDURE
4. Front Bumper - 5. Rear Bumper

B5M0379
3) Remove two clips from lower center of bumper.
B5M0281
4) Remove bolts from bumper stays.
B5M0282
5) Remove rear bumper assembly.
B5M0407
3. OUTBACK WITH STEP ROOF
1) Remove one clip from side of bumper.
2) Open rear gate and remove rear quarter trim lid.
B5M0408
3) Remove five bolts from lower center of bumper.
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5-1SERVICE PROCEDURE
5. Rear Bumper

B5M0409
4) Remove bolts from bumper stays.
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 extremely careful to prevent scratches on
bumper face as it is made of resin.

Be careful not to scratch the body when removing or
installing bumper.

To facilitate installation of rear bumper, attach slider
to the guide pin.

To facilitate installation of rear bumper, insert the
bumper hook into the body groove.
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5. Rear Bumper

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 resin.

Be careful not to scratch the body when removing or
installing bumper.

To facilitate installation of rear bumper, attach slider
to the guide pin.

To facilitate installation of rear bumper, insert the
bumper hook into the body groove.
B5M0380A
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5. Rear Bumper

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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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 lustre 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 classifica-
tion of the extent of damage.
1. 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“feathering”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“3.”section, depending on the
degree and nature of damage.
Polish the waxed area with a clean cloth after 5
to 10 minutes.
2. 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 dam-
aged 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“1.”section.Perform process No. 12 and subsequent opera-
tions in the“3.”section.
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5-1SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper

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 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 Remove parts built into bumper 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 suitable solvent
(NRM No. 900 precleno, white gasoline, or alcohol).
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“vee-out”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 sol-
vent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.
G5M0166
NOTE:

Do not melt welding rod until it flows out. This results in reduced strength.

Leave the welded spot unattended until it cools completely.
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5-1SERVICE PROCEDURE
7. Repair Instructions for Colored 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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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