SUBARU LEGACY 1999 Service Repair Manual

3) Lower door glass 10 to 15 mm (0.39 to 0.59 in)
from fully closed position. While applying outward
pressure (load) to upper edge of glass above mid-
point of two outer stabilizers, press inner stabilizer
until it just touches the glass, then secure it.
Load: F
Front door glass 39 N (4 kg, 9 lb)
Rear door glass 34.3 N (3.5 kg, 7.7 lb)
G5M0421
IRemedy for unequal dimensions,
between upper, lower and center pillar
sides
1) Close front door and raise door glass
2) Make sure of unequal dimensions.
G5M0498
3) If glass tilts to far rearward, loosen adjusting nut
(C) and adjust glass to be parallel with center pillar,
then after adjustment, tighten adjusting nut (C).
B5M0073B
IRemedy for improper glass to center
pillar clearance
1) Close front door and raise door glass
2) Make sure of improper clearance.
B5M0074A
3) If clearance is improper, loosen adjusting nut
(A), bolt (A) and adjust glass to center pillar.
B5M0075B
IRemedy for improper upper stop point
of door glass
1) Loosen front and rear sash stoppers.
22
5-2[W2B4]SERVICE PROCEDURE
2. Door

2) Increase the upward travel of window glass up
to the position where upper edge just touches
weatherstrip surface with door closed.
G5M0511
3) After adjustment, temporarily tighten stoppers.
NOTE:
Make sure that each glass stopper is touched.
IRemedy for incorrect contact of door
glass to weatherstrip
1) Close front door and raise door glass.
2) If clearance is below specifications, loosen bolt
(A) and bolt (B).
3) If clearance is over specifications, tighten bolt
(A) and bolt (B).
B5M0076A
IFit adjustment
Door glass fit is adjusted by displacing the glass
front edge with a stabilizer.
NOTE:
Before adjusting glass fit, visually check to deter-
mine relative adjusting positions of retainer and
molding (on roof side) and glass surface.1) Alternately adjust two rear sash adjusting bolts
(A) until dimensions (indicated in figure) are
obtained.
B5M0076A
CAUTION:
Do not loosen two adjusting nuts (A) at the
same time, as this moves sash fore and aft,
creating unequal glass- to-sash clearance. Dur-
ing adjustment, loosen only one nut and keep
the other tightened.
NOTE:
Always adjust two rear sash adjusting bolts (A) by
the same amount. Do not adjust the adjusting bolts
with sash bracket inclined toward inner panel, as
this increases effort required to operate regulator.
B5M0077A
2) Adjust front sash fit using rear sash adjustment
procedure outlined above as a guide. Two adjust-
ing bolts must be adjusted by the same amount.
NOTE:
Front and rear sash adjustment procedures are
basically the same; however, the amount of adjust-
ment is not always the same due to alignment dis-
persion of individual doors.
Adjust front and rear sash fit, as equally as pos-
sible. Otherwise, effort required to operate regula-
tor may increase.
3) After adjusting front sash-to-glass fit, secure
front sash.
23
[W2B4]5-2SERVICE PROCEDURE
2. Door

5. REAR DOOR GLASS
Alignment of rear door glass is basically the same as for the front door glass. Due to slight difference in
adjustment dimensions for fore-aft, up-down, and in-out alignments, key points for rear door adjustment are
described.
B5M0078B
24
5-2[W2B5]SERVICE PROCEDURE
2. Door

IFore-aft adjustment
1) Door glass alignment must be adjusted so that
glass- to-center pillar fit is equal at all points.
B5M0074A
NOTE:
If dimensions are smaller than those indicated,
glass will be caught in weatherstrip and may not
raise to the fully closed position.
2) After making fore-aft adjustment, raise and
lower glass to ensure it is free from any binding.
IFit adjustment
Increasing contact pressure causes rear door
glass to be caught in center pillar upper and lower
weatherstrip; this will cause premature weather-
strip wear.
B5M0076A
C: INSPECTION
1. FRONT AND REAR DOOR GLASS
1) Close front door and make sure of all clearances.
B5M0079A
2) If any clearance is not correct, adjust affected
parts. Re-check all clearances.
CAUTION:
IRepeatedly adjust parts until all clearances
are correct.
IAfter clearance adjustment, make sure that
all adjusting bolts and nuts are tightened.
25
[W2C1]5-2SERVICE PROCEDURE
2. Door

3. Rear Gate
A: REMOVAL AND INSTALLATION
CAUTION:
IBe careful not to scratch coated surfaces of
vehicle body and window glass during
removal. Place a cloth over the affected area.
IBe careful not to damage trim panels.
IUse an assistant when handling heavy parts.
IBe careful not to damage or lose small parts.
1. REAR GATE ASSEMBLY
1) Remove clips from trim panel and detach trim
panel.
CAUTION:
Be careful not to damage clips or their holes.
B5M0080
2) Disconnect rear washer hose from wiper motor.
3) Remove high-mount stop light.
4) If disconnected harness is re-used, tie connec-
tor with a string and place on the upper side of rear
gate for ready use.
5) Remove both rubber ducts and then extract
washer hose and harness connector.
CAUTION:
Do not forcefully pull cords, lead wires, etc.
since damage may result; carefully extract
them in a wavy motion while holding connec-
tors.
6) Remove both rubber ducts and then extract
washer hose and harness connector.
7) Gas stay
(1) Completely open rear gate.(2) Remove bolts which hold gas stay to rear
gate.
CAUTION:
IBe careful because rear gate drops while
removing bolts. Have an assistant support it
while removing bolts.
IBe sure to place a folded cloth between rear
gate and body to prevent scratches.
B5M0081
8) Remove the bolts which hold rear gate to hinge
and then detach rear gate.
B5M0082
9) General precautions in handling rear gate gas
stay.
CAUTION:
IDo not attempt to disassemble gas stay
because its cylinder is filled with gas.
IBefore discarding gas stay, place it at a
slight angle with the cylinder body side facing
up and drilla2to3mm(0.08 to 0.12 in) dia.
hole to completely discharge the content. (Gas
is odorless, colorless and harmless; however,
metal powder may come out of the hole.)
G5M0551
26
5-2[W3A0]SERVICE PROCEDURE
3. Rear Gate

IIt is good practice to place a vinyl sack over
it before drilling the hole because oil may spurt
out. Be careful to prevent vinyl cover from
becoming entangled on the drill.
G5M0491
IBe careful not to scratch the exposed sec-
tion of piston rod or allow oil or paint to come
in contact with it.
IDo not attempt to rotate the extended piston
rod.
10) Installation is in the reverse order of removal.
CAUTION:
IBe sure to add sealer to hinge.
IWhen installing rear gate, be careful not to
damage coating on body and rear gate.
2. LATCH
1) Remove trim panel.
2) Disengage rod from holder (= key cylinder).
3) Remove bolts from auto-door lock actuator.
4) Remove bolts from latch, and detach latch.
G5M0404
5) Disconnect rear gate switch connector.
6) Disconnect auto-door lock actuator connector.
7) Detach latch.
8) Installation is in the reverse order of removal.
3. OUTER HANDLE
1) Remove trim panel.
2) Disconnect rod from outer handle.3) Remove two nuts used to hold outer handle to
the inside of rear gate, and detach outer handle.
CAUTION:
Be careful not to damage packing when remov-
ing outer handle.
B5M0083
4) Installation is in the reverse order of removal.
4. KEY CYLINDER
1) Remove trim panel.
2) Disengage rod from holder (A).
3) Remove nut from key cylinder, and detach key
cylinder.
B5M0084C
4) Installation is in the reverse order of removal.
5. STRIKER
1) Remove two bolts from striker and detach
striker.
B5M0085
2) Installation is in the reverse order of removal.
27
[W3A5]5-2SERVICE PROCEDURE
3. Rear Gate

6. WEATHERSTRIP
1) Place weatherstrip so that its joints meet at
lower center of vehicle body, and install by insert-
ing flanged portion from below, as shown in section
AÐA in figure.
G5M0492
2) Tap along entire length with a rubber hammer to
firmly insert body flange into weatherstrip.
CAUTION:
IBe careful not to install in wrong direction.
IInstall weatherstrip carefully and firmly.
G5M0552
B: ADJUSTMENT
1) Loosen striker screw.
2) For lateral adjustment, align striker and latch at
their centers.
B5M0086
28
5-2[W3A6]SERVICE PROCEDURE
3. Rear Gate

4. Procedure Chart for Removing and Installing Window Glass
A: REMOVAL AND INSTALLATION
B5M0450A
29
[W4A0]5-2SERVICE PROCEDURE
4. Procedure Chart for Removing and Installing Window Glass

B: MATERIALS REQUIRED FOR
APPLICATION
Description Remarks
Repair adhesive set
ICartridge of single liquid
urethane adhesive
IPrimer for glass and bodySunstar No. 580 or Essex
Chemical Corp's Urethane E
Sunstar No. 435-580
Windshield knife or piano
wireFor cutting windshield.
Sealant gun For applying adhesive.
Suction cups For holding glass.
Putty knife For finishing adhesion sur-
face and cutting spacer.
Sponge For applying primer.
Gauze or cloth For cleaning.
Alcohol or white gasoline Alcohol or white gasoline
For cleaning adhesion sur-
face.
Tape For preventing damage to
painted surface.
5. Windshield
A: REMOVAL
1. USING WINDSHIELD KNIFE
The following procedure for the front windshield
can also be applied to other window glass.
1) Remove wiper arm and cowl panel.
2) Remove front side molding and front molding
upper.
B5M0087A
3) Remove glass:
(1) Put protective tape on body to prevent dam-
age.
(2) Apply soapy water to the surface of the
adhesive agent so the knife blade slides
smoothly.
(3) Cut off excess adhesive agent.
(4) Put windshield knife into layer of adhesive
(5) Cut adhesive layer with the windshield
knife.
G5M0418
30
5-2[W4B0]SERVICE PROCEDURE
5. Windshield

B: MATERIALS REQUIRED FOR
APPLICATION
Description Remarks
Repair adhesive set
ICartridge of single liquid
urethane adhesive
IPrimer for glass and bodySunstar No. 580 or Essex
Chemical Corp's Urethane E
Sunstar No. 435-580
Windshield knife or piano
wireFor cutting windshield.
Sealant gun For applying adhesive.
Suction cups For holding glass.
Putty knife For finishing adhesion sur-
face and cutting spacer.
Sponge For applying primer.
Gauze or cloth For cleaning.
Alcohol or white gasoline Alcohol or white gasoline
For cleaning adhesion sur-
face.
Tape For preventing damage to
painted surface.
5. Windshield
A: REMOVAL
1. USING WINDSHIELD KNIFE
The following procedure for the front windshield
can also be applied to other window glass.
1) Remove wiper arm and cowl panel.
2) Remove front side molding and front molding
upper.
B5M0087A
3) Remove glass:
(1) Put protective tape on body to prevent dam-
age.
(2) Apply soapy water to the surface of the
adhesive agent so the knife blade slides
smoothly.
(3) Cut off excess adhesive agent.
(4) Put windshield knife into layer of adhesive
(5) Cut adhesive layer with the windshield
knife.
G5M0418
30
5-2[W4B0]SERVICE PROCEDURE
5. Windshield