Subaru 2004 Forester, Service Manual

Page: 473 / 622

EI-27
EXTERIOR/INTERIOR TRIM
Front 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)
Pro-
cess
No.
Process name Job contents
1 Bumper removal Remove the bumper as required.
2 Part removal Remove the parts built into bumper as required.
3 Bumper placement
Place the bumper on a paint worktable as
required.
It is recommended that contour of worktable
accommodate internal shape of bumper.
(1) Bumper
(2) Set bumper section
4
Surface prepara-
tion Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol).
5 Cutting
If 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.
(1) Paint surface
(2) PP base surface
(3) 20 — 30 mm (0.79 — 1.18 in)
(4) 3 mm (0.12 in)
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 welding
Grind 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.
(1) Welded spot (Use heater gun and PP welding rod)
(2) PP base surface
(3) Beveled section
NOTE:
• Do not melt the welding rod until it flows out. This results in reduced strength.
• Leave the welded spot unattended until it cools completely.
EI-00038
(1)
(2)
EI-00235
(4)
(2)
(1)
(3)
EI-00236
(1)
(2)
(3)