Subaru Legacy IV (2008 year). Service manual - part 1075

GW-27

Windshield Glass

GLASS/WINDOWS/MIRRORS

B: INSTALLATION

1) Clean the external circumference of windshield
glass with alcohol or white gasoline.
2) Remove the adhesive layer on the body using
cutter knife to obtain smooth face of 2 mm (0.08 in)
thick.

CAUTION:
Be careful not to damage the body and paint
surface.

3) Clean the body with alcohol or white gasoline to
eliminate cutting powder, dust and dirt completely
from body.

4) Install the dam rubber.

5) Fit the mark (B) on molding to the notch (A) of
glass side, and install the molding to entire perime-
ter of glass.

(1) Adhesive

(2) 2 mm (0.08 in)

(3) Dam rubber

(4) Glass

(4)

(2)

(1)

(3)

GW-00071

(1) Locating pin (adhered)

(2) Dam rubber

(3) 11 mm (0.433 in)

(4) 11 mm (0.433 in)

(5) 9 mm (0.354 in)

(1)

(3)

(4)

(5)

(2)

GW-00572

(A)

(B)

GW-00570

GW-28

Windshield Glass

GLASS/WINDOWS/MIRRORS

6) Apply two types of primers to the adhesive layer
of glass using sponge.

Glass primer:

Dow Automotive
ESSEX U-401, U-402

7) Apply the primer to the adhesive layer of body.

Painted surface primer:

Dow Automotive
ESSEX U-413

NOTE:
• Primer once attached to the painted surface of
the body and internal trim is hard to wipe off. Mask
the circumference of such area.
• Let primer dry for about ten minutes before in-
stalling the glass.
• Do not touch the surface coated with primer.

8) Cut off the cartridge nozzle tip as shown and set
it in sealant gun.

9) Apply adhesive to the glass end surface as shown.

Adhesive:

Dow Automotive
ESSEX U-400HV or equivalent

10) Fit the locating pins, and install windshield
glass using suction rubber cup.

11) Lightly press the windshield glass for tight fit.
12) Make flush the adhesive surface jutted out us-
ing spatula.
13) After completion of all work, allow the vehicle to
stand for about 24 hours.

NOTE:
• When door is opened/closed after glass is bond-
ed, always lower the door glass first, and then
open/close it carefully.
• Move the vehicle slowly.
• For minimum drying time and vehicle standing
time before driving after bonding, follow instruc-
tions or instruction manual from the adhesive man-
ufacturer.
14) After curing of adhesive, pour the water on ex-
ternal surface of vehicle to check that there are no
water leaks.

NOTE:
When a vehicle is returned to the user, tell him or
her that the vehicle should not be subjected to
heavy impact for at least three days.
15) Install the cowl panel. <Ref. to EI-40, INSTAL-
LATION, Cowl Panel.>
16) Connect the wiper deicer connector and attach
the front pillar trim of the passenger’s side. (Model
with wiper deicer)

(1) Application of primer

(2) Glass side

(3) Body side

(1) 10 mm (0.39 in)

(2) 9 mm (0.35 in)

(3)

(2)

(1)

GW-00073

GW-00494

(1)

(2)

(2)

60

(1) 9 — 12 mm (0.35 — 0.47 in)

(1)

GW-00239

GW-00045

GW-29

Rear Gate Glass

GLASS/WINDOWS/MIRRORS

14.Rear Gate Glass

A: REMOVAL

1) Remove the rear wiper motor.
<Ref. to WW-18, REMOVAL, Rear Wiper Motor.>
2) Disconnect the electrical connectors from rear
defogger terminal.
3) Remove the glass in the same procedure as for
windshield glass. <Ref. to GW-26, REMOVAL,
Windshield Glass.>

B: INSTALLATION

1) Apply adhesive in the same procedure as for
windshield glass. <Ref. to GW-27, INSTALLA-
TION, Windshield Glass.>
2) Insert the glass clip pin into rear gate hole, push
on the area around the clip pin to secure it, and
then push lightly all around the area to seal it.
3) About one hour after installation, conduct a leak
test.

4) After completion of all work, allow the vehicle to
stand for about 24 hours.

NOTE:
• When door is opened/closed after glass is bond-
ed, always lower the door glass first, and then
open/close it carefully.
• Move the vehicle slowly.
• For minimum drying time and vehicle standing
time before driving after bonding, follow instruc-
tions or instruction manual from the adhesive man-
ufacturer.
• When a vehicle is returned to the user, tell him or
her that the vehicle should not be subjected to
heavy impact for at least three days.
5) Connect the rear defogger terminals.
6) Install the rear wiper.
<Ref. to WW-18, INSTALLATION, Rear Wiper Mo-
tor.>

(1) Upside

(2) Molding

(3) Glass

(4) Adhesive

(5) Downside

(6) Glass

(7) Molding

(8) Adhesive

(1)

(5)

(4)

(8)

(2)

(3)

(7)

(6)

GW-00240

GW-30

Rear Window Glass

GLASS/WINDOWS/MIRRORS

15.Rear Window Glass

A: REMOVAL

1) Disconnect the ground cable from the battery.
2) Disconnect the electrical connectors from rear
defogger terminal.
3) Remove the glass in the same procedure as for
windshield glass. <Ref. to GW-26, REMOVAL,
Windshield Glass.>

B: INSTALLATION

1) Adhere the dam rubber.

2) Install the glass in the same procedure as for
windshield glass. <Ref. to GW-27, INSTALLA-
TION, Windshield Glass.>
3) Connect the rear defogger and antenna terminal
connectors.

4) After completion of all work, allow the vehicle to
stand for about 24 hours.

NOTE:
• When door is opened/closed after glass is bond-
ed, always lower the door glass first, and then
open/close it carefully.
• Move the vehicle slowly.
• For minimum drying time and vehicle standing
time before driving after bonding, follow instruc-
tions or instruction manual from the adhesive man-
ufacturer.
5) After curing of adhesive, pour the water on exter-
nal surface of vehicle to check that there are no wa-
ter leaks.

NOTE:
When a vehicle is returned to the user, tell him or
her that the vehicle should not be subjected to
heavy impact for at least three days.

(1) Locating pin (adhered)

(2) Dam rubber

(3) 11 mm (0.433 in)

(4) 4 mm (0.157 in)

(5) Rear window glass

(6) 40 mm (1.575 in)

(1)

(2)

(2)

(5)

(3)

(3)

GW-00436

(4)

(6)