1999 SUBARU LEGACY Service Repair Manual

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.
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5-2[W2A1]SERVICE PROCEDURE
2. Door

CAUTION:
Be careful because cover may break if sealer is
removed forcefully.
G5M0391
4) Installation is in the reverse order of removal.
NOTE:
IConfirm that sealer is properly applied without
breaks. Then install sealing cover.
IWhen repairing or replacing sealing cover, use
ªCEMEDINE 5430Lº as sealer. It may be overlaid
on existing sealer.
Sealer:
CEMEDINE 5430L
CAUTION:
IAny breaks in sealer can cause water leak-
age or entry of air and dust. Be sure sealer is
applied in a continuous line.
IDo not stop up drain hole (A) with sealer.
IDo not stop up install hole with (B) sealing
cover.
B5M0062C
IMake sure sealing cover bonded areas are
free from wrinkles or openings.
4. CHECKER
1) Remove trim panel.
2) Remove sealing cover. 3) Apply a cloth to door and body to prevent dam-
aging them, and remove checker pin by driving it
upward.
CAUTION:
Be careful not to damage door and body.
G5M0392
4) Completely close door glass.
5) Loosen two nuts securing checker, and take out
checker through access hole in underside.
6) 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 (A).
B5M0070C
4) Remove inner remote.
5) Remove inner stabilizer (A).
B5M0063C
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[W2A5]5-2SERVICE 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:
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5-2[W2A6]SERVICE PROCEDURE
2. Door

(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.
B5M0067
6) Loosen screws securing both latch and
actuator, then remove latch and actuator assembly
through service hole in bottom.
G5M0396
7) Installation is in the reverse order of removal.
Tightening torque:
6.4
±2.0 N´m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
NOTE:
ICheck operation of each part.
ICheck each sliding part for proper lubrication.
CAUTION:
After installation, be sure lock mechanism
operates normally.
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.
B5M0068
5) 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)
9. KEY LOCK
1) Remove trim panel.
2) Remove sealing cover.
3) Completely close door glass.
4) Remove outer handle.
5) Loosen spring (A) securing key lock.
B5M0069C
6) Remove key lock from outer handle.
7) 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.
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[W2A9]5-2SERVICE 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
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5-2[W2A10]SERVICE PROCEDURE
2. Door

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 Ð 1.5 mm (0.020 Ð 0.059 in)
B5M0574A
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)
B5M0573A
2) Loosen the front and rear glass upper stopper
fixate bolts. Adjust the front door glass upper limit
position, then re-adjust the gusset until dimension
B is within the specified range.
DIMENSION B:
3Ð5mm(0.12 Ð 0.20 in)
B5M0575A
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[W2B2]5-2SERVICE PROCEDURE
2. Door

3. PROCEDURE CHART FOR ADJUSTING DOOR GLASS
B5M0449A
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5-2[W2B3]SERVICE PROCEDURE
2. Door

4. FRONT DOOR GLASS
B5M0072B
IDoor 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.
21
[W2B4]5-2SERVICE PROCEDURE
2. Door