Subaru 2009 IMPREZA, Service Manual

Page: 3199 / 3619

EI-33
Front Bumper
EXTERIOR/INTERIOR TRIM
3) Deep damage such as a break or hole that requires filling
Much of the peripheral grained surface must be sacrificed for repair. 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 the bumper as required.
2 Removal of parts Remove the parts built into bumper as required.
3 Bumper placement
Place the bumper on a paint worktable as
required.
It is recommended to use the paint worktable
conforming to 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, etc.).
5 Cutting
If the damage is a crack or a hole, 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 base
surface. Next, use a knife or grinder to carve a
V-shaped groove in the area for repair.
(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 the beveled surface with sand paper (#40 — #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 — #60) and clean using a
solvent.
Temporarily spot-weld the side, using PP welding rod and heater gun.
(1) Welded point (Use heater gun and PP welding rod)
(2) PP base surface
(3) Beveled section
NOTE:
• Do not melt welding rod until it flows out. This results in reduced strength.
• Leave the welded spot unattended until it cools completely.
EI-00234
(2)
(1)
EI-00235
(4)
(2)
(1)
(3)
EI-00236
(1)
(2)
(3)