1997 SUBARU LEGACY service

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

G5M0412
NOTE:
A matching pin is cemented to the corners of glass on
compartment side. Use a piano wire when cutting each pin.
G5M0412
2. WAGON MODEL
NOTE:
It is impossible to remove the molding from the glass.
If molding is broken, replace rear glass.
1) Remove rear wiper and rear gate trim.
2) Disconnect connector from rear defogger terminal.
3) Remove glass in the same manner as in windshield.
CAUTION:
In case of using a piano wire, when re-installing the old
rear window glass, be careful not to damage molding.
NOTE:
A matching pin is cemented to corners of glass on com-
partment side. Use a piano wire when cutting each pin.
B5M0089A
B: INSTALLATION
1. 4 DOOR MODEL
1) Install glass in the same manner as in windshield.
2) Stick dam rubber

1.
3) While aligning ceramic print notch

2on rear window
glass with marks in the center of upper and lower moldings,
install the two moldings on rear window glass.
4) Make rear defogger connections.
5) After installation, test for water leakage after about one
hour, and leave vehicle alone for 24 hours.
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5-2SERVICE PROCEDURE
6. Rear Window Glass

2. WAGON MODEL
B5M0090A
1) Install rear gate trim.
2) Install glass in the same manner as in windshield.
3) About one hour after installation, test for water leakage.
Leave vehicle for 24 hours before using it.
4) Connect rear defogger connections.
5) Install high-mount stop light and rear wiper.
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5-2SERVICE PROCEDURE
6. Rear Window Glass