SUBARU LEGACY 1997 Service Repair Manual

B5M0467A
11. REAR DOOR CATCHER
1) Open the rear door.
2) Using TORX
®BIT (Tamper resistant type), remove rear
door catcher.
3) Installation is in the reverse order of removal.
Tightening torque:
37±10 N⋅m (3.8±1.0 kg-m, 27.5±7.2 ft-lb)
B: ADJUSTMENT
1. DOOR ASSY
1) Using ST, loosen bolts securing upper and lower hinges
to body, and adjust fore-and-aft and vertical alignment of
door.
ST 925610000 DOOR HINGE WRENCH
B5M0071A
2) Loosen mounting screws approximately one rotation.
Adjust striker

1position by lightly tapping with hammer. (To
adjust, utilize the shape of striker nut plate

2support.)
CAUTION:
Use cloth to prevent damaging body or other parts.
Do not directly tap striker plastic portion.
Do not apply impact on spot-welded striker nut
plate.
Hinge tightening torque (body side):
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
Striker tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
19
5-2SERVICE PROCEDURE
2. Door

B5M0574A
2. GUSSET
Loosen the 3 bolts and 1 nut securing the gusset. Rotate
the gusset in the direction of the arrow until dimension A is
within the specified range.
DIMENSION A:
0.5 — 1.5 mm (0.020 — 0.059 in)
B5M0573A
NOTE:
If dimension A is not within the specified range, adjust the
front door glass upper limit position as outlined in steps (1)
and (2).
(1) Raise the front door glass to the upper limit position
and set the SPACER (FRONT DOOR) in position.
ST 62065FA100 SPACER (FRONT DOOR)
B5M0575A
(2) Loosen the front and rear glass upper stopper fix-
ate bolts. Adjust the front door glass upper limit
position, then re-adjust the gusset until dimension B is
within the specified range.
DIMENSION B:
3 — 5 mm (0.12 — 0.20 in)
20
5-2SERVICE PROCEDURE
2. Door

2. PROCEDURE CHART FOR ADJUSTING DOOR
GLASS
Insert door glass.
Mount door glass on regulator.
Install front and rear upper stoppers.

Install inner stabilizer.
Align upper stopper position.
Align adjusting bolt with nut.
Remedy for unequal dimensions

Remedy for improper window glass-to-center
pillar clearance

Remedy for improper window glass-
to-weatherstrip contact

Not O.K. Not O.K. Not O.K.
Close the door and check all clearances are as specified.
O.K.
END









21
5-2SERVICE PROCEDURE
2. Door

3. FRONT DOOR GLASS
B5M0072A
G5M0421
Door glass fit adjustment
Before adjusting door glass alignment, ensure adjusting
bolts for stabilizers, upper stoppers and sashes are loose
and glass is raised so that it is in contact with upper and
side weatherstrip.
1) Temporarily tighten one of the two rear sash adjusting
bolts, at midpoint of oblong hole on inner panel.
2) Temporarily tighten B channel regulator at a position
slightly lower than midpoint of oblong hole on inner panel.
22
5-2SERVICE PROCEDURE
2. Door

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 midpoint 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)
G5M0498
Remedy for unequal dimensions, between upper,
lower and center pillar sides
1) Close front door and raise door glass.
2) Make sure of unequal dimensions.
B5M0073A
3) If glass tilts to far rearward, loosen adjusting nut
Cand
adjust glass to be parallel with center pillar, then after
adjustment, tighten adjusting nut

C.
B5M0074A
Remedy for improper glass to center pillar clearance
1) Close front door and raise door glass.
2) Make sure of improper clearance.
23
5-2SERVICE PROCEDURE
2. Door

B5M0075A
3) If clearance is improper, loosen adjusting nut
A, bolt
A
and adjust glass to center pillar.
G5M0511
Remedy for improper upper stop point of door glass
1) Loosen front and rear sash stoppers.
2) Increase the upward travel of window glass up to the
position where upper edge just touches weatherstrip sur-
face with door closed.
3) After adjustment, temporarily tighten stoppers.
NOTE:
Make sure that each glass stopper is touched.
B5M0076A
Remedy for incorrect contact of door glass to weath-
erstrip
1) Close front door and raise door glass.
2) If clearance is below specifications, loosen bolt

Aand
bolt

B.
3) If clearance is over specifications, tighten bolt

Aand
bolt

B.
B5M0076A
Fit adjustment
Door glass fit is adjusted by displacing the glass front edge
with a stabilizer.
NOTE:
Before adjusting glass fit, visually check to determine rela-
tive adjusting positions of retainer and molding (on roof
side) and glass surface.
1) Alternately adjust two rear sash adjusting bolts

Auntil
dimensions (indicated in figure) are obtained.
CAUTION:
Do not loosen two adjusting nuts

Aat the same time,
as this moves sash fore and aft, creating unequal
glass-to-sash clearance. During adjustment, loosen
only one nut and keep the other tightened.
24
5-2SERVICE PROCEDURE
2. Door

B5M0077A
NOTE:
Always adjust two rear sash adjusting bolts

Aby the same
amount. Do not adjust the adjusting bolts with sash bracket
inclined toward inner panel, as this increases effort
required to operate regulator.
2) Adjust front sash fit using rear sash adjustment proce-
dure outlined above as a guide. Two adjusting bolts must
be adjusted by the same amount.
NOTE:
Front and rear sash adjustment procedures are basically
the same; however, the amount of adjustment is not always
the same due to alignment dispersion of individual doors.
Adjust front and rear sash fit, as equally as possible.
Otherwise, effort required to operate regulator may
increase.
3) After adjusting front sash-to-glass fit, secure front sash.
25
5-2SERVICE PROCEDURE
2. Door

4. 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 below.
B5M0078A
B5M0074A
Fore-aft adjustment
1) Door glass alignment must be adjusted so that glass-
to-center pillar fit is equal at all points. Always use dimen-
sions (indicated in figure) as a guide during adjustment.
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.
26
5-2SERVICE PROCEDURE
2. Door

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.
27
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.
28
5-2SERVICE PROCEDURE
3. Rear Gate