1999 SUBARU LEGACY Service Repair Manual

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

CAUTION:
IKeep knife edge along glass surface and end
face.
IWhen first putting knife into layer of
adhesive, select point with wide gap between
body and glass.
NOTE:
A matching pin is cemented to corners of glass on
compartment side.
Use a piano wire when cutting each pin.
G5M0412
2. USING PIANO WIRE
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) 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.
G5M0494
(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.
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.
G5M0553
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 alco-
hol or white gasoline.
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.
31
[W5B0]5-2SERVICE PROCEDURE
5. Windshield

(3) Put matching pin on body and glass in sev-
eral places.
G5M0407
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 (A) on wind-
shield upper portion with mark (B) in center of
upper front molding, install upper front molding on
windshield.
B5M0088C
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:
IPrimer is hard to wipe off of body paint,
instrument panel, inner trim, etc. So put mask-
ing around these areas for protection.
IAfter application, let 1st primer dry sponta-
neously for about 10 minutes.
IDo not touch primer-coated surface under
any circumstances.
G5M0495
8) Application of adhesive:
(1) Cut nozzle tip of cartridge as shown in fig-
ure.
G5M0408
(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.
9) Installation of glass:
(1) Hold glass with rubber suction cups.
(2) Mount glass on body with matching pin
aligned.
G5M0409
32
5-2[W5B0]SERVICE PROCEDURE
5. Windshield

(3) Stick them fast by pressing all sides lightly.
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 gaso-
line.
G5M0496
(2) Install front side molding.
CAUTION:
Do not open and close door after moldings
have been installed. When opening and closing
door for unavoidable reason, lower door glass
and gently move door.
11) Water leakage test:
Test for water leakage about one hour after instal-
lation.
CAUTION:
IMove vehicle very gently.
IDo 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. SEDAN
1) Disconnect connector from rear defogger termi-
nal.
2) Remove glass in the same manner as in wind-
shield.
NOTE:
A matching pin is cemented to the corners of glass
on compartment side. Use a piano wire when cut-
ting each pin.
G5M0412
2. WAGON
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 termi-
nal.
3) Remove glass in the same manner as in wind-
shield.
CAUTION:
In case of using a piano wire, when re-install-
ing the old rear window glass, be careful not to
damage molding.
NOTE:
A matching pin is cemented to corners of glass on
compartment side. Use a piano wire when cutting
each pin.
G5M0412
33
[W6A2]5-2SERVICE PROCEDURE
6. Rear Window Glass

(3) Stick them fast by pressing all sides lightly.
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 gaso-
line.
G5M0496
(2) Install front side molding.
CAUTION:
Do not open and close door after moldings
have been installed. When opening and closing
door for unavoidable reason, lower door glass
and gently move door.
11) Water leakage test:
Test for water leakage about one hour after instal-
lation.
CAUTION:
IMove vehicle very gently.
IDo 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. SEDAN
1) Disconnect connector from rear defogger termi-
nal.
2) Remove glass in the same manner as in wind-
shield.
NOTE:
A matching pin is cemented to the corners of glass
on compartment side. Use a piano wire when cut-
ting each pin.
G5M0412
2. WAGON
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 termi-
nal.
3) Remove glass in the same manner as in wind-
shield.
CAUTION:
In case of using a piano wire, when re-install-
ing the old rear window glass, be careful not to
damage molding.
NOTE:
A matching pin is cemented to corners of glass on
compartment side. Use a piano wire when cutting
each pin.
G5M0412
33
[W6A2]5-2SERVICE PROCEDURE
6. Rear Window Glass

B: INSTALLATION
1. SEDAN
1) Install glass in the same manner as in wind-
shield.
2) Stick dam rubber (A).
3) While aligning ceramic print notch (B) on rear
window glass with marks in the center of upper and
lower moldings, install the two moldings on rear
window glass.
B5M0089C
4) Make rear defogger connections.
5) After installation, test for water leakage after
about one hour, and leave vehicle alone for 24
hours.
2. WAGON
B5M0090A
1) Install rear gate trim.
2) Install glass in the same manner as in wind-
shield.
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.
34
5-2[W6B1]SERVICE PROCEDURE
6. Rear Window Glass

7. Rear Quarter Glass
A: REMOVAL
1. SEDAN
B5M0091A
1) Remove rear quarter molding. 2) Remove glass in the same manner as in wind-
shield.
2. WAGON
B5M0092A
1) Remove rear quarter molding.
2) Remove glass in the same manner as in windshield.
35
[W7A2]5-2SERVICE PROCEDURE
7. Rear Quarter Glass