1995 SUBARU LEGACY window

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.
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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.
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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.
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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.
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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









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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.
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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

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