SUBARU LEGACY 1995 Service Repair Manual

4. Rear Door Glass
B5M0055A

1Glass


2Regulator and motor ASSY


3Regulator handle (Except power window)


4Retainer spring


5Regulator ASSY
Tightening torque: N⋅m (kg-m, ft-lb)
T: 7.4±2.0 (0.75±0.2, 5.4±1.4)
6
5-2COMPONENT PARTS
4. Rear Door Glass

5. Rear Gate and Glass
B5M0056A

1Rear gate


2Key cylinder


3Outer handle


4Door lock actuator


5Striker


6Latch


7Glass pin

8Glass


9Buffer


10Stopper


11Gas stay


12Hinge


13Rear gate handle
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T3: 13±3 (1.3±0.3, 9.4±2.2)
T4: 14±4 (1.4±0.4, 10.1±2.9)
T5: 25±5 (2.5±0.5, 18.1±3.6)
7
5-2COMPONENT PARTS
5. Rear Gate and Glass

6. Door Lock Assembly
1. FRONT DOOR
B5M0057A

1Holder remote


2Inner remote ASSY


3Door outer handle


4Striker


5Door latch


6Switch ASSY


7Auto-door lock actuator


8Bell crank


9Rod holder
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T3: 14±4 (1.4±0.4, 10.1±2.9)
8
5-2COMPONENT PARTS
6. Door Lock Assembly

2. REAR DOOR
B5M0058A

1Door outer handle


2Door latch


3Door lock actuator


4Striker


5Rod holder


6Holder remote


7Inner remote ASSY
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T3: 14±4 (1.4±0.4, 10.1±2.9)
9
5-2COMPONENT PARTS
6. Door Lock Assembly

7. Door Trim
B5M0059A

1Trim panel


2Gusset cover


3Arm rest


4Ornament


5Bracket

6Pocket


7Weatherstrip


8Rear gate upper trim


9Rear gate lower trim
10
5-2COMPONENT PARTS
7. Door Trim

8. Weatherstrip
B5M0060A

1Rear gate weatherstrip


2Retainer and molding


3Upper and side weatherstrip

4Retainer (Center)


5Weatherstrip (Rear door)


6Weatherstrip (Front door)
11
5-2COMPONENT PARTS
8. Weatherstrip

1. Procedure Chart for Removing and
Installing Door and Related Parts
NOTE:
This flow chart shows the main procedures for removing
and installing the door and its related parts. For details,
refer to the text.
DoorDoor lock systemDoor regulator

Door glass

Remove door trim parts, etc.

REMOVALRemove front and rear upper stoppers
and stabilizer (inner).

Remove door.Disconnect joints
between latch, outer
handle, key lock and
remote assembly.Separate door glass from regulator.
Remove guide
channel B.Remove door
glass.
Remove door
lock system.Remove
regulator.
Install door.Install door
lock system.Install regulator.
Install guide
channel.Insert door glass.

Adjust door alignment.Adjust door
lock system.Mount door glass on regulator.

INSTALLATION
AND
ADJUSTMENTAdjust striker.Link latch, outer handle,
key lock and remote
assembly together.Install front and rear upper stoppers
and stabilizer (inner).

Adjust glass position.

Install door trim parts, etc.

Confirm.












12
5-2SERVICE PROCEDURE
1. Procedure Chart for Removing and Installing Door and Related Parts

G5M0486
2. Door
A: REMOVAL AND INSTALLATION
1. DOOR ASSY
1) Remove lower trim and disconnect connectors from
body harness.
2) Place a cloth or a wood block under door to prevent
damage, and support it with a jack.
3) Remove checker pin by driving it upward. Be careful not
to damage door and body.
G5M0385
4) Remove bolts (M8) securing upper and lower hinges to
door, and remove door from hinges.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
5) Remove hinges by loosening hinges mounting bolt (M8)
off of body.
Tightening torque:
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
CAUTION:
Work carefully to avoid damaging door.
6) Installation is in the reverse order of removal.
NOTE:
Apply grease to moving parts of door hinges.
B5M0329A
2. TRIM PANEL
1) Press retainer spring

1with a thin flat bladed screw-
driver and then remove regulator handle

2. (models with-
out power window)
B5M0061A
2) Remove gusset cover
1and three screws.
13
5-2SERVICE PROCEDURE
2. Door

G5M0390
3) Using ST, disengage the clip.
ST 925580000 PULLER
4) Remove trim panel and then disconnect connector.
(models with power window)
CAUTION:
Be careful not to break clip by applying undue force.
Installation is in the reverse order of removal.
G5M0391
3. SEALING COVER
1) Remove trim panel. <Ref. to 5-2 [W2A2].>
2) Remove speaker, remote assembly and disconnect
connectors.
3) Remove sealer with a spatula.
CAUTION:
Be careful because cover may break if sealer is
removed forcefully.
4) Install in reverse order of removal. Some special items
will be described below.
5) Confirm that sealer is properly applied without breaks.
Then install sealing cover.
6) When repairing or replacing sealing cover, use “CEME-
DINE 5430L” as sealer. It may be overlaid on existing
sealer.
Sealer:
CEMEDINE 5430L
B5M0062A
CAUTION:
Any breaks in sealer can cause water leakage or
entry of air and dust. Be sure sealer is applied in a
continuous line.
Do not stop up drain hole

1with sealer.
Do not stop up install hole

2with sealing cover.
Make sure sealing cover bonded areas are free from
wrinkles or openings.
14
5-2SERVICE PROCEDURE
2. Door

G5M0392
4. CHECKER
1) Remove trim panel. <Ref. to 5-2 [W2A2].>
2) Remove sealing cover. <Ref. to 5-2 [W2A3].>
3) Apply a cloth to door and body to prevent damaging
them, and remove checker pin by driving it upward.
CAUTION:
Be careful not to damage door and body.
4) Completely close door glass.
5) Loosen two nuts securing checker, and take out
checker through access hole in underside.
Installation should be made in the reverse order of
removal.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
5. DOOR GLASS
1) Remove trim panel. <Ref. to 5-2 [W2A2].>
2) Remove sealing cover. <Ref. to 5-2 [W2A3].>
3) Disconnect door mirror connector and then remove
gusset

1. <Ref. to 5-2 [W2A10].>
4) Remove inner remote. <Ref. to 5-2 [W2A6].>
B5M0063A
5) Remove inner stabilizer
1.
B5M0064A
6) Remove nut and then separate glass holder
1from
guide channel A

2.
NOTE:
When removing nut, move door window lower glass con-
necting section to service hole of door panel.
7) Remove window glass upward.
CAUTION:
After removing window glass, do not move regulator.
15
5-2SERVICE PROCEDURE
2. Door