Subaru Legacy (2005 year). Service manual — part 1011
EB-21
EXTERIOR BODY PANELS
Rear Door
6. Rear Door
A: REMOVAL
1. REAR DOOR PANEL
1) Disconnect the ground cable from battery.
2) Remove the rear door trim. <Ref. to EI-48, RE-
MOVAL, Door Trim.>
3) Remove the rear speaker. <Ref. to ET-9, RE-
MOVAL, Rear Speaker.>
4) Pull back the sealing cover. <Ref. to EB-24, RE-
MOVAL, Rear Sealing Cover.>
5) Remove the rear door glass. <Ref. to GW-24,
REMOVAL, Rear Door Glass.>
6) Remove the door sash and rear door regulator
and motor assembly. <Ref. to GW-26, REMOVAL,
Rear Regulator and Motor Assembly.>
7) Remove the rear door latch. <Ref. to SL-32, RE-
MOVAL, Rear Door Latch and Door Lock Actuator
Assembly.>
8) Remove the rear outer handle. <Ref. to SL-31,
REMOVAL, Rear Outer Handle.>
9) Remove the screw to remove the door trim
bracket.
10) Remove the rear door inner weather strip.
NOTE:
If the weather strip clip is removed with excessive
force, the weather strip may be damaged. Be sure
to use clip remover to remove.
11) Remove the bolts and nuts to remove the door
checker.
12) Remove the rear door. <Ref. to EB-22, REAR
DOOR ASSEMBLY, REMOVAL, Rear Door.>
EB-00152
(A) Pin clip
(B) Weather strip clip
EB-00156
(A)
(B)
(A)
EB-00141
EB-00154
EB-22
EXTERIOR BODY PANELS
Rear Door
2. REAR DOOR ASSEMBLY
1) Disconnect the ground cable from battery.
2) Remove the center pillar lower trim. <Ref. to EI-
60, REMOVAL, Lower Inner Trim.>
3) Remove the center pillar inner protector lower.
4) Remove the harness holder (A), and disconnect
the door harness connector inside pillar.
5) Put a wooden block on jack and place jack under
the rear door. Support the rear door with the jack to
protect it from damage.
6) Remove the bolt from the door checker.
7) Remove the door-side bolts for upper and lower
hinges to remove the rear door panel.
8) Remove the door hinge from vehicle.
B: INSTALLATION
1. REAR DOOR PANEL
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion”. <Ref. to EB-9, REAR DOOR PANEL,
COMPONENT, General Description.>
2. REAR DOOR ASSEMBLY
1) Put a wooden block on jack and place the rear
door on that.
2) Apply grease to sliding area of the door hinges.
3) Install the rear door to upper hinge and lower
hinge adjusting by jack.
4) Tighten the bolt of door checker.
5) Connect the door harness connector, and install
the center pillar inner protector.
6) Install the center pillar lower trim.
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion”. <Ref. to EB-9, REAR DOOR PANEL,
COMPONENT, General Description.>
SB-00144
EB-00153
(A)
EB-00013
EB-00014
EB-00015
EB-00013
EB-23
EXTERIOR BODY PANELS
Rear Door
C: ADJUSTMENT
1) Open the rear door, loosen the door-side bolts of
upper and lower hinges to align the position of rear
door panel longitudinally and laterally.
2) Loosen the screws (A), and tap the striker (B)
using plastic hammer to adjust the gap between
rear end surface of rear door panel and body sur-
face.
CAUTION:
Do not use an impact wrench. Welding area on
the striker nut plate is easily broken.
EB-00015
EB-00017
(B)
(A)
EB-24
EXTERIOR BODY PANELS
Rear Sealing Cover
7. Rear Sealing Cover
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the rear door trim. <Ref. to EI-48, RE-
MOVAL, Door Trim.>
3) Pull back the sealing cover.
NOTE:
• Carefully remove the butyl tape. Excessive force
will easily break the cover.
• If cover gets broken, replace it with a new one.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing the sealing cover, use the butyl
tape.
3) Press the butyl tape-applied area firmly to pre-
vent any floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
• Apply a uniform bead of butyl tape.
• Attach the sealing cover, keeping it from becom-
ing wrinkled.
• Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If the sealing cover gets damaged, replace it with a
new one.
EB-00018
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