Subaru Legacy BN/BS (2015-2019) Service Manual: Installation
1. FRONT DOOR PANEL 1. Put a wooden block and the like on a jack and place the panel assembly - front door on it.
2. Adjust the height by the jack, and temporarily install the panel assembly - front door to the upper hinge - front door and the lower hinge - front door. NOTE: • When installing the panel assembly - front door, make sure that a uniform clearance is created around the panel. • Perform installation while paying attention to the assembly direction of the grommet. 3. Adjust the clearance around the panel assembly - front door. Front Door > ADJUSTMENT 4. Tighten the mounting bolts of the panel assembly - front door to the specified torque. Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) 5. Tighten the bolts and nuts of the checker assembly - front door. Tightening torque: Refer to “COMPONENT” of “General Description”. General Description > COMPONENT 6. Connect door harness connector, and install the cover side sill - front and the front cover - side sill. Lower Inner Trim > INSTALLATION 7. Attach the door sash tape. Door Sash Tape > INSTALLATION 8. Before installing each part, check the following items. • Rod of the latch and actuator assembly - front is free from deformation. • Grease is applied sufficiently to the rod joints of the latch and actuator assembly - front. • Cable of the latch and actuator assembly - front is free from deformation such as fray. • Grease is applied sufficiently to the cable joints of the latch and actuator assembly - front. 9. Install door internal parts in the reverse order of removal. • Weather strip - front door • Handle - door outer Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) • Latch & actuator assembly - front Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) • Regulator & motor assembly - front for the front door Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) • Running channel - front door CAUTION: Check that the running channel - front door is securely fixed to the panel assembly - front door and to the sash COMPL - partition. • Glass assembly - front door, and glass - front door partition Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) 10. Install the front door impact sensor. CAUTION: • Do not reuse the bolt and nut. Always replace with the specified new bolts and nuts. • Thoroughly clean the sensor mounting area before installing the front door impact sensor. • When installing the sensor, insert the set pin on the backside of the sensor into the hole on the body side securely. Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) 11. Install the cover B pillar - front door INN. CAUTION: Always replace with a new part, because engagement of the claw weakens. 12. Install the front door speaker assembly. 13. Install the outer mirror assembly. Outer Mirror Assembly > INSTALLATION Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) 14. Install the sealing cover. Front Sealing Cover > INSTALLATION 15. Install the trim panel - front door. Door Trim > INSTALLATION 16. Install the garnish assembly - door. (OUTBACK model) Side Garnish > INSTALLATION 17. Connect the ground terminal to battery sensor. NOTE 2. FRONT DOOR HINGE 1. Apply grease to the sliding area of door hinges, and install the door hinge to vehicle. Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb) 2. Adjust the height by the jack, and temporarily install the panel assembly - front door to the upper hinge - front door and the lower hinge - front door. NOTE: When installing the panel assembly - front door, make sure that a uniform clearance is created around the panel. 3. Adjust the clearance around the panel assembly - front door. Front Door > ADJUSTMENT 4. Tighten the bolts of the panel assembly - front door to the specified torque. Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) 5. Connect door harness connector, and install the cover side sill - front and the front cover - side sill. Lower Inner Trim > INSTALLATION 6. Tighten the bolts on the vehicle side of the checker assembly - front door. Tightening torque: Refer to “COMPONENT” of “General Description”. General Description > COMPONENT 7. Install the garnish assembly - door. (OUTBACK model) Side Garnish > INSTALLATION 8. Connect the ground terminal to battery sensor. NOTE |
Adjustment
Adjust the clearance around the panel assembly - front door as follows.PartStandardAFender COMPL - front to Panel assembly - front door4.2±1.25 mm (0.17±0.05 in)BPanel assembly - front door to Side ...
Front fender
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Other materials:
Inspection
1. KEYLESS TRANSMITTER BATTERY1. Measure the keyless transmitter battery voltage.Preparation tool:Circuit testerNOTE:Complete the measurement within 5 seconds because the battery discharges during measurement.Battery terminalInspection ConditionsStandard(+) — (−)Connect resistor (A) 47 -2.5 ...
