SUBARU LEGACY 1996 Service Repair Manual

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.
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.
2) Remove sealing cover.
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.
2) Remove sealing cover.
3) Disconnect door mirror connector and then remove
gusset

1.
4) Remove inner remote.
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

B5M0065
8) Remove regulator installing bolt and guide channel B
installing nut.
9) Remove regulator through lower service hole of door
panel.
10) Installation is in the reverse order of removal.
G5M0394
6. INNER REMOTE
1) Remove trim panel.
2) Remove sealing cover.
3) Disconnect joints of two rods.
4) Unlatch rod holder.
B5M0066A
5) Remove remote holder
1and then remove inner
remote assembly

2.
6) Installation is in the reverse order of removal. Some
special items will be described below.
7) After passing two rods through holder, attach remote
assembly to inner panel.
8) Latch rod holder.
B5M0330A
9) Lock the door and then loosen bolt
1.
10) Lower bell-crank

2and then tighten bolt
2.
NOTE:
If rear door is equipped with child safety lock, check that
child lock lever moves without dragging.
16
5-2SERVICE PROCEDURE
2. Door

7. DOOR LATCH
1) Remove trim panel.
2) Remove inner remote assembly.
3) Remove sealing cover around latch service hole. to 5-2 [W2A3].>
4) Completely close door glass.
B5M0067
5) Remove latch and actuator assembly.
(1) Turn rod holder to disconnect joint between key
lock and rod.
(2) Turn rod holder to disconnect joint between outer
handle and rod.
(3) Turn rod holder to disconnect joint between crank
and rod.
G5M0396
6) Loosen screws securing both latch and actuator, then
remove latch and actuator assembly through service hole
in bottom.
Tightening torque (screw):
6.4±2.0 N⋅m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
7) Installation is in the reverse order of removal.
Some special items will be described below.
8) Check operation of each part.
9) Check each sliding part for proper lubrication.
CAUTION:
After installation, be sure lock mechanism operates
normally.
17
5-2SERVICE PROCEDURE
2. Door

B5M0068
8. OUTER HANDLE
1) Remove trim panel.
2) Remove sealing cover.
3) Detach door latch rod from outer handle and key lock.
4) Loosen nut securing outer handle and then remove
outer handle from outside.
CAUTION:
Be careful not to damage door.
Installation is 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)
B5M0069A
9. KEY LOCK
1) Remove trim panel.
2) Remove sealing cover.
3) Completely close door glass.
4) Remove outer handle.
5) Loosen spring

1securing key lock.
6) Remove key lock from outer handle.
Installation is in the reverse order of removal.
NOTE:
Install so that key slot in key lock comes to center of hole
in outer handle.
B5M0070A
10. GUSSET
NOTE:
Be sure window is all the way down.
1) Remove trim panel.
2) Remove door rearview mirror.
3) Remove sealing cover.
4) Remove bolts and nuts which secure gusset.
5) Lift out gusset

1.
To install, reverse the above removal procedures.
18
5-2SERVICE PROCEDURE
2. Door