Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 736
EI-31
Front Bumper
EXTERIOR/INTERIOR TRIM
7. Front Bumper
A: REMOVAL
1. FRONT BUMPER FACE
1) Disconnect the ground cable from battery.
2) Attach the protective tape to the headlight.
3) Remove the clip of the front grille.
4) Remove the clip that secures the front mud
guard and front bumper.
5) Remove the clips at the lower side of bumper.
6) Disconnect the fog light connector. (Model with
fog light)
(a) Headlight
(b) Front bumper and fender panel
(c) Protective tape
EI-03374
(a)
(b)
(c)
EI-02028
EI-01784
EI-01968
EI-32
Front Bumper
EXTERIOR/INTERIOR TRIM
7) Detach the flange sections on the bumper face
side from guide bracket (A).
CAUTION:
Do not pull forcibly. It may damage the flange
sections of the bumper face.
NOTE:
It is easier to detach them from the fender side in
the order from (1) to (5), while pulling up the
bumper face to the direction of arrow (B) (upward).
8) Remove the bumper face from vehicle body.
9) Remove the front grille from bumper face. <Ref.
to EI-26, REMOVAL, Front Grille.>
10) Remove the fog light from bumper face. <Ref.
to LI-21, REMOVAL, Front Fog Light Assembly.>
11) Remove the side cover from bumper face.
(1) Remove clips (A).
(2) Remove the upper and lower claws.
2. FRONT BUMPER BEAM ASSEMBLY
1) Disconnect the ground cable from battery.
2) Remove the front bumper face. <Ref. to EI-31,
FRONT BUMPER FACE, REMOVAL, Front
3) Remove the bolts, and remove the bumper
beam assembly from vehicle body.
NOTE:
After all bolts are removed, raise the whole bumper
beam a little to remove it from vehicle body.
B: INSTALLATION
1) Install each part in the reverse order of removal.
NOTE:
Fit the bumper face to the gap (B) between the
guide bracket (A) and fender securely.
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion”. <Ref. to EI-6, FRONT BUMPER, COM-
2) Adjust the fog light beam. (model with fog light)
<Ref. to LI-21, FOG LIGHT AIMING, ADJUST-
MENT, Front Fog Light Assembly.>
EI-03375
(1)
(2)
(4)
(5)
(B)
(3)
EI-01723
(1)
(2)
(3)
(B)
(A)
EI-01959
(A)
EI-01786
EI-01725
(A)
(B)
EI-33
Front Bumper
EXTERIOR/INTERIOR TRIM
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Pro-
cess
No.
Process name
Job contents
1
Bumper installation
Place the bumper on a paint worktable as
required. Use the paint worktable conforming to
inner shape of bumper if possible.
(1) Bumper
(2) Set bumper section
2
Masking
Mask specified part (black base) with masking tape. Use masking tape for PP.
3
Degreasing/clean-
ing
Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
4
Primer paint
Apply primer to all parts to be painted, using spray gun. Use primer (clear).
5
Drying
Dry 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)
Non-colored
Metallic paint
Use section (block) paint for top coat.
For paint/hardener mixture, observe the specifi-
cations recommended by the manufacturers.
• Viscosity: 10 — 13 sec./20°C (68°F)
• Film thickness: 35 — 45 µ
• Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kgf/cm
2
, 36 — 50 psi)
Use section (block) paint for top coat.
For paint/hardener mixture, observe the specifi-
cations recommended by the manufacturers.
• Viscosity: 10 — 13 sec./20°C (68°F)
• Film thickness: 15 — 20 µ
• Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kgf/cm
2
, 36 — 50 psi)
7
Drying
Not required.
Dry at normal temperature [at least 10 min. 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 minute intervals.
For paint/hardener mixture, observe the specifi-
cations recommended by the manufacturers.
• Viscosity: 14 — 16 sec./20°C (68°F)
• Film thickness: 25 — 30 µ
• Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kgf/cm
2
, 36 — 50 psi)
9
Drying
60°C (140°F), 60 min. or 80°C (176°F), 30 min.
If the temperature is higher than 80°C (176°F), PP may be deformed. Keep maximum tempera-
ture at 80°C (176°F) or less.
10
Inspection
Check paint.
11
Removal of mask-
ing
Remove the masking tape applied in procedure 2.
EI-00234
(2)
(1)
EI-34
Front Bumper
EXTERIOR/INTERIOR TRIM
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER
NOTE:
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be re-
stored to its former condition. Damages limited to the shallow scratches that cause only a change in the luster
of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this
point to the customer and obtain an understanding about the matter.
Repair methods are outlined below, based on a classification of the extent of damage.
1) Minor damage causing only a change in the luster of the bumper due to a light touch
Almost restorable.
2) Deep damage caused by scratching with fences etc.
A dent cannot be repaired but a whitened or swelled part can be removed.
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.)
Pro-
cess
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
Finish
Resin section
Coated section
Repeatedly apply wax to the affected area
using soft cloth (such as flannel).
Recommended wax: Tire wax or equivalent
Perform either the same procedures as for the
resin section or process No. 18 and subse-
quent in section 3), depending on the degree
and nature of damage.
Polish the waxed area with clean cloth after 5 —
10 minutes.
Pro-
cess
No.
Process name
Job contents
1
Cleaning
Clean the damaged area with water.
2
Removal of dam-
aged area
Cut off protruding area, if any, due to collision, using a putty knife.
3
Sanding
Grind the affected area with #100 — #500 sand paper.
4
Finish
Resin section
Coated section
Same as process No. 3 in section 1).
Perform process No. 12 and subsequent opera-
tions in section 3).
Pro-
cess
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
(white gasoline or alcohol, etc.).
EI-00234
(2)
(1)
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