SUBARU LEGACY 1995 Service Repair Manual

B5M0076A
Fit adjustment
Increasing contact pressure causes rear door glass to be
caught in center pillar upper and lower weatherstrip; this
will cause premature weatherstrip wear. For this reason,
always use dimensions indicated below as a guide during
glass fit adjustment.
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:
Repeatedly adjust parts until all clearances are cor-
rect.
After clearance adjustment, make sure that all
adjusting bolts and nuts are tightened.
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5-2SERVICE PROCEDURE
2. Door

3. Rear Gate
A: REMOVAL AND INSTALLATION
CAUTION:
Be careful not to scratch coated surfaces of vehicle
body and window glass during removal. Place a cloth
over the affected area.
Be careful not to damage trim panels.
Use an assistant when handling heavy parts.
Be careful not to damage or lose small parts.
B5M0080
1. REAR GATE ASSEMBLY
1) Remove clips from trim panel and detach trim panel.
CAUTION:
Be careful not to damage clips or their holes.
2) Disconnect connectors and terminal.
3) Disconnect rear washer hose from wiper motor.
4) Remove high-mount stop light.
5) If disconnected harness is re-used, tie connector with a
string and place on the upper side of rear gate for ready
use.
CAUTION:
Do not forcefully pull cords, lead wires, etc. since dam-
age may result; carefully extract them in a wavy motion
while holding connectors.
6) Remove both rubber ducts and then extract washer
hose and harness connector.
B5M0081
7) Gas stay
(1) Completely open rear gate.
(2) Remove bolts which hold gas stay to rear gate.
CAUTION:
Be careful because rear gate drops while removing
bolts. Have an assistant support it while removing
bolts.
Be sure to place a folded cloth between rear gate
and body to prevent scratches.
B5M0082
8) Remove the bolts which hold rear gate to hinge and
then detach rear gate.
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5-2SERVICE PROCEDURE
3. Rear Gate

G5M0551
9) General precautions in handling rear gate gas stay.
CAUTION:
Do not attempt to disassemble gas stay because its
cylinder is filled with gas.
Before discarding gas stay, place it at a slight angle
with the cylinder body side facing up and drilla2to3
mm (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.)
G5M0491
It 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.
Be careful not to scratch the exposed section of
piston rod or allow oil or paint to come in contact with
it.
Do not attempt to rotate the extended piston rod.
10) Installation is in the reverse order of removal.
CAUTION:
Be sure to add sealer to hinge.
When installing rear gate, be careful not to damage
coating on body and rear gate.
G5M0404
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.
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.
B5M0083
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 removing
outer handle.
4) Installation is in the reverse order of removal.
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5-2SERVICE PROCEDURE
3. Rear Gate

B5M0084A
4. KEY CYLINDER
1) Remove trim panel.
2) Disengage rod from holder

1.
3) Remove nut from key cylinder, and detach key cylinder.
4) Installation is in the reverse order of removal.
B5M0085
5. STRIKER
Remove two bolts from striker and detach striker.
G5M0492
6. WEATHERSTRIP
1) Place weatherstrip so that its joints meet at lower cen-
ter of vehicle body, and install by inserting flanged portion
from below, as shown in section A—A in figure.
2) Tap along entire length with a rubber hammer to firmly
insert body flange into weatherstrip.
CAUTION:
Be careful not to install in wrong direction.
Install weatherstrip carefully and firmly.
G5M0552
B5M0086
B: ADJUSTMENT
1) Loosen striker screw.
2) For lateral adjustment, align striker and latch at their
centers.
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5-2SERVICE PROCEDURE
3. Rear Gate

4. Procedure Chart for Removing and
Installing Window Glass
1. PROCEDURES OF REMOVAL AND INSTALLATION
Removal of molding
Removal of glass
BodyGlass
Finishing and cleaning of adhesion
surface
Cleaning of adhesion surface
Application of primer
Application of primer

Application of adhesive
Installation of glass
Installation of molding
Removal of excess adhesive
Check for water leakage.
2. MATERIALS REQUIRED FOR APPLICATION
Description Remarks
Repair adhesive set
Cartridge of single liquid
urethane adhesive
Primer for glass and bodySunstar No. 580 or Essex
Chemical Corp’s Urethane E
Sunstar No. 435-580
Windshield knife or piano wire For cutting windshield.
Sealant gun For applying adhesive.
Suction cups For holding glass.
Putty knifeFor finishing adhesion surface and
cutting spacer.
Sponge For applying primer.
Gauze or cloth For cleaning.
Alcohol or white gasoline For cleaning adhesion surface.
TapeFor preventing damage to painted
surface.








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5-2SERVICE PROCEDURE
4. Procedure Chart for Removing and Installing Window Glass

B5M0087A
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.
G5M0418
3) Remove glass.
(1) Put protective tape on body to prevent damage.
(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.
CAUTION:
Keep knife edge along glass surface and end face.
When first putting knife into layer of adhesive, select
point with wide gap between body and glass.
G5M0412
NOTE:
A matching pin is cemented to corners of glass on com-
partment side.
Use a piano wire when cutting each pin.
B5M0087A
2. USING PIANO WIRE
1) Remove wiper arm and cowl panel.
2) Remove front side molding and front molding upper.
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5-2SERVICE PROCEDURE
5. Windshield

G5M0494
3) Remove glass.
(1) Put protective tape on body to prevent damage.
(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.
(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.
G5M0553
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.
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 alcohol or white
gasoline.
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5-2SERVICE PROCEDURE
5. Windshield

G5M0407
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.
(3) Put matching pin on body and glass in several
places.
B5M0088A
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

1on windshield upper
portion with mark

2in center of upper front molding, install
upper front molding on windshield.
G5M0495
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:
Primer is hard to wipe off of body paint, instrument
panel, inner trim, etc. So put masking around these
areas for protection.
After application, let 1st primer dry spontaneously
for about 10 minutes.
Do not touch primer-coated surface under any cir-
cumstances.
G5M0408
8) Application of adhesive
(1) Cut nozzle tip of cartridge as shown in figure.
(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.
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5-2SERVICE PROCEDURE
5. Windshield

G5M0409
9) 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.
G5M0496
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 gasoline.
(2) Install front side molding.
CAUTION:
Do not open and close door after moldings have been
installed. When opening and closing door for unavoid-
able reason, lower door glass and gently move door.
11) Water leakage test
Test for water leakage about one hour after installation.
CAUTION:
Move vehicle very gently.
Do 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. 4 DOOR MODEL
1) Disconnect connector from rear defogger terminal.
2) Remove glass in the same manner as in windshield.
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5-2SERVICE PROCEDURE
5. Windshield - 6. Rear Window Glass

G5M0409
9) 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.
G5M0496
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 gasoline.
(2) Install front side molding.
CAUTION:
Do not open and close door after moldings have been
installed. When opening and closing door for unavoid-
able reason, lower door glass and gently move door.
11) Water leakage test
Test for water leakage about one hour after installation.
CAUTION:
Move vehicle very gently.
Do 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. 4 DOOR MODEL
1) Disconnect connector from rear defogger terminal.
2) Remove glass in the same manner as in windshield.
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5-2SERVICE PROCEDURE
5. Windshield - 6. Rear Window Glass