Window SUBARU LEGACY 1999 Service User Guide

4. Front Door Glass
B5M0054B
(1) Glass
(2) Regulator and motor ASSY
(3) Regulator handle (Except power
window)(4) Retainer spring
(5) Regulator ASSYTightening torque: N´m (kg-m, ft-lb)
T:
7.4±2.0 (0.75±0.2, 5.4±1.4)
6
5-2[C400]COMPONENT PARTS
4. Front Door Glass

5. Rear Door Glass
B5M0055B
(1) Glass
(2) Regulator and motor ASSY
(3) Regulator handle (Except power
window)(4) Retainer spring
(5) Regulator ASSYTightening torque: N´m (kg-m, ft-lb)
T:
7.4±2.0 (0.75±0.2, 5.4±1.4)
7
[C500]5-2COMPONENT PARTS
5. Rear Door Glass

2. Door
A: REMOVAL AND INSTALLATION
1. DOOR ASSEMBLY
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.
G5M0486
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.
G5M0385
CAUTION:
Work carefully to avoid damaging door.
6) Installation is in the reverse order of removal.
Tightening torque:
29
±5 N´m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
NOTE:
Apply grease to moving parts of door hinges.
2. TRIM PANEL
1) Press retainer spring (A) with a thin flat bladed
screwdriver and then remove regulator handle (B).
(models without power window)
B5M0329D
2) Remove gusset cover (A) and three screws.
B5M0061C
3) Using ST, disengage the clip.
ST 925580000 PULLER
G5M0390
4) Remove trim panel and then disconnect con-
nector. (models with power window)
CAUTION:
Be careful not to break clip by applying undue
force.
5) Installation is in the reverse order of removal.
3. SEALING COVER
1) Remove trim panel.
2) Remove speaker, remote assembly and discon-
nect connectors.
3) Remove sealer with a spatula.
14
5-2[W2A1]SERVICE PROCEDURE
2. Door

6) Remove nut and then separate glass holder (A)
from guide channel A (B).
B5M0064C
NOTE:
When removing nut, move door window lower
glass connecting section to service hole of door
panel.
7) Remove window glass upward.
CAUTION:
After removing window glass, do not move
regulator.
8) Remove regulator installing bolt and guide
channel B installing nut.
B5M0065
9) Remove regulator through lower service hole of
door panel.
10) Installation is in the reverse order of removal.
6. INNER REMOTE
1) Remove trim panel.
2) Remove sealing cover.
3) Disconnect joints of two rods.
G5M0394
4) Unlatch rod holder.
5) Remove remote holder (A) and then remove
inner remote assembly (B).
B5M0066C
6) Installation is in the reverse order of removal.
NOTE:
IAfter passing two rods through holder, attach
remote assembly to inner panel.
ILatch rod holder.
7) Lock the door and then loosen bolt (A).
8) Lower bell-crank (B) and then tighten bolt (A).
B5M0330C
NOTE:
If rear door is equipped with child safety lock,
check that child lock lever moves without dragging.
7. DOOR LATCH
1) Remove trim panel.
2) Remove inner remote assembly. [W2A6].>
3) Remove sealing cover around latch service
hole.
4) Completely close door glass.
5) Remove latch and actuator assembly:
16
5-2[W2A6]SERVICE PROCEDURE
2. Door

10. GUSSET
1) Be sure window is all the way down.
2) Remove trim panel.
3) Remove door rearview mirror.
4) Remove sealing cover.
5) Remove bolts and nuts which secure gusset
(A).
6) Lift out gusset (A).
B5M0070D
7) Installation is in the reverse order of removal.
11. REAR DOOR CATCHER
1) Open the rear door.
2) Using TORXTBIT (Tamper resistant type),
remove rear door catcher.
B5M0467A
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 ASSEMBLY
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
2) Loosen mounting screws approximately one
rotation. Adjust striker (A) position by lightly tap-
ping with hammer. (To adjust, utilize the shape of
striker nut plate support (B).)
CAUTION:
IUse cloth to prevent damaging body or other
parts.
IDo not directly tap striker plastic portion.
IDo 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)
B5M0071C
18
5-2[W2A10]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

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

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