SUBARU LEGACY 1999 Service Repair Manual

CAUTION:
IKeep knife edge along glass surface and end
face.
IWhen first putting knife into layer of
adhesive, select point with wide gap between
body and glass.
NOTE:
A matching pin is cemented to corners of glass on
compartment side.
Use a piano wire when cutting each pin.
G5M0412
2. USING PIANO WIRE
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) Using drill or putty knife, make through-hole
(one place) in adhesive agent.(3) Pass piano wire through the hole from
inside the compartment, and connect both ends
of wire securely to wooden blocks.
G5M0494
(4) Cut adhesive layer with the wire by pulling
it back and forth.
CAUTION:
When making through-hole into adhesive layer
and cutting the adhesive, be careful not to
damage interior and exterior parts.
B: INSTALLATION
1) After cutting layer of adhesive, remove dam
rubber remaining on body.
2) Finishing adhesion surface on body side:
Using a cutter knife etc., cut layer of adhesive
sticking firmly to body, and finish it to a smooth
surface of about 2 mm (0.08 in) in thickness.
CAUTION:
Take extra care not to cause damage to body
paint.
G5M0553
3) Cleaning body surface:
(1) Thoroughly remove chips, dirt and dust
from body surface.
(2) Clean body wall surface and upper surface
of layer of adhesive with a solvent such as alco-
hol or white gasoline.
4) Positioning glass:
(1) Mount glass on body.
(2) Adjust position of glass so that gap between
body and glass is uniform on all sides.
31
[W5B0]5-2SERVICE PROCEDURE
5. Windshield

(3) Put matching pin on body and glass in sev-
eral places.
G5M0407
5) Cleaning glass:
(1) Dismount glass from body
(2) Clean surface of glass to be adhered with
alcohol or white gasoline.
6) Stick dam rubber and install front molding
upper:
While aligning ceramic print notch (A) on wind-
shield upper portion with mark (B) in center of
upper front molding, install upper front molding on
windshield.
B5M0088C
7) Application of primer:
(1) Using a sponge, apply primer to part of
glass to be adhered.(2) Apply primer to part of body to be adhered.
CAUTION:
IPrimer is hard to wipe off of body paint,
instrument panel, inner trim, etc. So put mask-
ing around these areas for protection.
IAfter application, let 1st primer dry sponta-
neously for about 10 minutes.
IDo not touch primer-coated surface under
any circumstances.
G5M0495
8) Application of adhesive:
(1) Cut nozzle tip of cartridge as shown in fig-
ure.
G5M0408
(2) Open cartridge and put it into a gun with
nozzle attached.
(3) Apply adhesive uniformly to all sides of
adhesion surface while operating gun along
glass end face.
9) Installation of glass:
(1) Hold glass with rubber suction cups.
(2) Mount glass on body with matching pin
aligned.
G5M0409
32
5-2[W5B0]SERVICE PROCEDURE
5. Windshield

(3) Stick them fast by pressing all sides lightly.
10) Installation of molding:
(1) Remove adhesive overflowing from outside
of glass until it becomes level with outer height
of glass. Then, add adhesive to portions that
need it, and clean with alcohol or white gaso-
line.
G5M0496
(2) Install front side molding.
CAUTION:
Do not open and close door after moldings
have been installed. When opening and closing
door for unavoidable reason, lower door glass
and gently move door.
11) Water leakage test:
Test for water leakage about one hour after instal-
lation.
CAUTION:
IMove vehicle very gently.
IDo not squirt strong hose stream on vehicle.
12) Spontaneous drying:
After completing all operations, leave vehicle alone
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him that
vehicle should not be subjected to heavy
shocks for at least three days.
13) Install cowl panel and wiper arm.
6. Rear Window Glass
A: REMOVAL
1. SEDAN
1) Disconnect connector from rear defogger termi-
nal.
2) Remove glass in the same manner as in wind-
shield.
NOTE:
A matching pin is cemented to the corners of glass
on compartment side. Use a piano wire when cut-
ting each pin.
G5M0412
2. WAGON
NOTE:
It is impossible to remove the molding from the
glass.
If molding is broken, replace rear glass.
1) Remove rear wiper and rear gate trim.
2) Disconnect connector from rear defogger termi-
nal.
3) Remove glass in the same manner as in wind-
shield.
CAUTION:
In case of using a piano wire, when re-install-
ing the old rear window glass, be careful not to
damage molding.
NOTE:
A matching pin is cemented to corners of glass on
compartment side. Use a piano wire when cutting
each pin.
G5M0412
33
[W6A2]5-2SERVICE PROCEDURE
6. Rear Window Glass

(3) Stick them fast by pressing all sides lightly.
10) Installation of molding:
(1) Remove adhesive overflowing from outside
of glass until it becomes level with outer height
of glass. Then, add adhesive to portions that
need it, and clean with alcohol or white gaso-
line.
G5M0496
(2) Install front side molding.
CAUTION:
Do not open and close door after moldings
have been installed. When opening and closing
door for unavoidable reason, lower door glass
and gently move door.
11) Water leakage test:
Test for water leakage about one hour after instal-
lation.
CAUTION:
IMove vehicle very gently.
IDo not squirt strong hose stream on vehicle.
12) Spontaneous drying:
After completing all operations, leave vehicle alone
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him that
vehicle should not be subjected to heavy
shocks for at least three days.
13) Install cowl panel and wiper arm.
6. Rear Window Glass
A: REMOVAL
1. SEDAN
1) Disconnect connector from rear defogger termi-
nal.
2) Remove glass in the same manner as in wind-
shield.
NOTE:
A matching pin is cemented to the corners of glass
on compartment side. Use a piano wire when cut-
ting each pin.
G5M0412
2. WAGON
NOTE:
It is impossible to remove the molding from the
glass.
If molding is broken, replace rear glass.
1) Remove rear wiper and rear gate trim.
2) Disconnect connector from rear defogger termi-
nal.
3) Remove glass in the same manner as in wind-
shield.
CAUTION:
In case of using a piano wire, when re-install-
ing the old rear window glass, be careful not to
damage molding.
NOTE:
A matching pin is cemented to corners of glass on
compartment side. Use a piano wire when cutting
each pin.
G5M0412
33
[W6A2]5-2SERVICE PROCEDURE
6. Rear Window Glass

B: INSTALLATION
1. SEDAN
1) Install glass in the same manner as in wind-
shield.
2) Stick dam rubber (A).
3) While aligning ceramic print notch (B) on rear
window glass with marks in the center of upper and
lower moldings, install the two moldings on rear
window glass.
B5M0089C
4) Make rear defogger connections.
5) After installation, test for water leakage after
about one hour, and leave vehicle alone for 24
hours.
2. WAGON
B5M0090A
1) Install rear gate trim.
2) Install glass in the same manner as in wind-
shield.
3) About one hour after installation, test for water
leakage. Leave vehicle for 24 hours before using
it.4) Connect rear defogger connections.
5) Install high-mount stop light and rear wiper.
34
5-2[W6B1]SERVICE PROCEDURE
6. Rear Window Glass

7. Rear Quarter Glass
A: REMOVAL
1. SEDAN
B5M0091A
1) Remove rear quarter molding. 2) Remove glass in the same manner as in wind-
shield.
2. WAGON
B5M0092A
1) Remove rear quarter molding.
2) Remove glass in the same manner as in windshield.
35
[W7A2]5-2SERVICE PROCEDURE
7. Rear Quarter Glass

B: INSTALLATION
1) Finish surface of adhesive layer on body.
Using a putty knife, etc., cut layer of adhesive stick
firmly to body and finish it into a smooth surface of
about 2 mm (0.08 in) in thickness.
CAUTION:
Be careful not to damage body finish.
G5M0497
2) Cleaning of body surface:
(1) Remove chips, dirt and dust from body sur-
face.
(2) Clean body wall surface and upper surface
of adhesive layer with a solvent such as alcohol
or white gasoline.
3) Cleaning glass:
(1) Remove dirt and dust from surface of glass
to be adhered.
(2) Clean surface of glass to be adhered with
alcohol or white gasoline.
4) Application of primer:
(1) Using a sponge, apply primer to surface of
glass to be adhered.
(2) Apply primer to surface of body to be
adhered.
CAUTION:
IIf primer has dropped on body finish, it is
hard to wipe it off. So protect with masking.
IPrimer must not project from black frame of
glass.
IAfter applying primer, let it dry spontane-
ously for about 10 minutes.
G5M0495
5) Application of adhesive:
(1) Cut nozzle tip as shown in figure.
G5M0414
(2) Open cartridge and put it into a gun with
nozzle attached.
(3) Apply adhesive uniformly to all sides of
adhesion surface while operating gun along
glass end face.
6) Installation of glass:
(1) Hold glass with rubber suction cups.
(2) Mount glass on body with matching pin
aligned.
(3) Stick them fast by pressing all sides lightly.
7) Water leakage test:
After installing glass, test for water leakage after
about one hour.
CAUTION:
IMove vehicle slowly.
IWhen opening and closing door, lower door
glass and move door gently.
IDo not squirt strong hose stream on vehicle.
8) Spontaneous drying:
After completing all operations, leave vehicle alone
for 24 hours.
CAUTION:
When delivering vehicle to user, tell him or her
that vehicle should not be subjected to heavy
shocks for at least three days.
36
5-2[W7B0]SERVICE PROCEDURE
7. Rear Quarter Glass

1. Door Glass
Condition Apparent cause/Correction
Glass in fully closed
position1) Glass runs out of weatherstrip lip when considerable hand
pressure is applied to it from inside.
G5M0502
IInsufficient upward travel of glass
Increase upward travel of glass.
(This condition may cause wind/booming noise during high-
speed operation.)
2) Clearance exists between glass and weatherstrip when
light hand pressure is applied to it at center and rear pillar
locations.
G5M0503
IInsufficient glass-to-door weather-
strip contact
Check stabilizer and glass for proper
contact. Increase contact using
upper sash adjustment bolt.
IImproper adjustment of striker in
in-out direction Close door and check
for alignment of striker with vehicle
body.
(This condition may cause wind noise and/or water leakage.)
3) Adjust door glass so that it is aligned with door rearview
mirror gusset.
G5M0504
IWindow is not properly adjusted in
up-down/fore-aft direction.
Adjust window. If necessary, move B
channel regulator to eliminate win-
dow tilt.
IGusset is not properly adjusted in
fore-aft direction.
Adjust gusset after loosing all bolts
and nuts witch tightening it.
37
[K100]5-2DIAGNOSTICS
1. Door Glass

Condition Apparent cause/Correction
Door in fully closed/
open position1) Glass rides over weatherstrip lip when door is closed.
G5M0505
IImproper up-down and in-out glass
alignments
Adjust glass for up-down and in-out
alignments (incl. rear sash, upper
stopper adjustment, etc.). If
necessary, correct glass tilt by mov-
ing B channel regulator.
(This condition increases wind/booming noise, leakage and/or
effort required to close door.)
2) Edge of glass contacts retainer when door is fully closed.
G5M0506
IImproper glass-to-center pillar
weatherstrip or excessive glass con-
tact to weatherstrip
IExcessive adjusting in contact to
weatherstrip
Causes rear edge of glass to tilt
inboard closer to center pillar. Adjust
rear sash adjustment bolt to reduce
glass contact to weatherstrip.
Raise or lower window
glass1) Considerable effort or time is required to operate regulator.
Standard operating effort:
IEntire up-down travel except for point 5 mm (0.20 in)
below fully closed position: 29.4 N (3.0 kg, 6.6 lb)
IPoint 5 mm (0.20 in) below fully closed position: 44.1 N
(4.5 kg, 9.9 lb)
G5M0507
ISliding resistance increased due
to high stabilizer-to-glass contact
pressure.
Reduce contact by mounting inner
stabilizer to inside of the vehicle.
IHigh glass-to-windshield contact
pressure
Reduce contact using upper sash
adjustment bolt.
IUnequal contact adjustment stroke
between front and rear sashes Set to
equal stroke.
ITilt of rear sash adjustment bolt
mounting bracket
Correct tilt of bracket so it is parallel
to inner panel.
38
5-2[K100]DIAGNOSTICS
1. Door Glass

Condition Apparent cause/Correction
Raise or lower window
glass2) Center pillar weatherstrip is caught by rear window glass
when glass is raised.
G5M0508
IImproper fore-aft or in-out align-
ment of window glass
Lower B channel regulator to tilt win-
dow glass back.
3) Window glass tilts forward by more than 2 mm (0.08 in).
G5M0509
IExcessive glass contact pressure
or improper in-out alignment
(1) Lower B channel regulator to tilt
window glass rearward.
(2) Reduce contact pressure using
upper sash adjustment bolt.
Excessive tilt of glass forward is due to excessive glass²con-
tact'' which causes reaction of center pillar weatherstrip.
Glass can be tilted forward due to increase in reaction of
shoulder weatherstrip or free play between sash and roller.
Taking these symptoms into account, glass should be
aligned.
39
[K100]5-2DIAGNOSTICS
1. Door Glass