Subaru Legacy IV (2008 year). Manual - part 1149

EB-16

Front Door

EXTERIOR BODY PANELS

4. Front Door

A: REMOVAL

1. FRONT DOOR PANEL

1) Disconnect the ground cable from the battery.
2) Remove the front door trim. <Ref. to EI-49, RE-
MOVAL, Door Trim.>
3) Remove the outer mirror assembly. <Ref. to
GW-20, REMOVAL, Outer Mirror Assembly.>
4) Remove the front door speaker. <Ref. to ET-7,
REMOVAL, Front Speaker.>
5) Remove the sealing cover. <Ref. to EB-19, RE-
MOVAL, Front Sealing Cover.>
6) Remove the gusset and front door glass. <Ref.
to GW-11, REMOVAL, Front Door Glass.>
7) Remove the door sash, and remove the front
door regulator and motor. <Ref. to GW-17, RE-
MOVAL, Front Regulator and Motor Assembly.>
8) Remove the front door latch assembly. <Ref. to
SL-36, REMOVAL, Front Door Latch and Door
Lock Actuator Assembly.>
9) Remove the front outer handle. <Ref. to SL-35,
REMOVAL, Front Outer Handle.>
10) Remove the screw to remove the door trim
bracket.

11) Remove the front door 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.

12) Remove the bolts and nuts to remove the door
checker.

13) Remove the front door. <Ref. to EB-17,
FRONT DOOR ASSEMBLY, REMOVAL, Front
Door.>

EB-00152

(A) Pin clip

(B) Weather strip clip

EB-00155

(A)

(B)

(A)

EB-00141

EB-00154

EB-17

Front Door

EXTERIOR BODY PANELS

2. FRONT DOOR ASSEMBLY

1) Disconnect the ground cable from the battery.
2) Remove the front pillar lower trim. <Ref. to EI-61,
REMOVAL, Lower Inner Trim.>
3) Remove the instrument panel lower cover or
glove box lower cover <Ref. to EI-51, REMOVAL,
Instrument Panel Lower Cover.> or <Ref. to EI-52,
REMOVAL, Glove Box.>
4) Disconnect the connector of door harness from
body harness.

5) Put a wooden block on jack and place jack under
the front door. Support the door with a jack to pro-
tect it from damage.

6) Remove the bolt from the door checker.

7) Remove the door-side bolts for upper and lower
hinges to remove front door panel.

8) Remove the door hinge from vehicle.

B: INSTALLATION

1. FRONT DOOR PANEL

Install in the reverse order of removal.

Tightening torque:

Refer to “COMPONENT” of “General Descrip-
tion”. <Ref. to EB-8, FRONT DOOR PANEL, 
COMPONENT, General Description.>

2. FRONT DOOR ASSEMBLY

1) Put a wooden block on jack and place the front
door on that.

2) Apply grease to the sliding area of door hinges,
and install the door hinge to vehicle.
3) Install the front door to upper hinge and lower
hinge adjusting by jack.
4) Tighten bolt of door checker.
5) Connect door harness connector, and install the
instrument panel lower cover.
6) Install the front pillar lower trim.

Tightening torque:

Refer to “COMPONENT” of “General Descrip-
tion”. <Ref. to EB-8, FRONT DOOR PANEL, 
COMPONENT, General Description.>

EB-00151

EB-00013

EB-00014

EB-00015

EB-00013

EB-18

Front Door

EXTERIOR BODY PANELS

C: ADJUSTMENT

1) Using the ST, loosen the body-side bolts of up-
per and lower hinges to align the position for verti-
cal and horizontal direction of the front door panel.
ST

925610000

DOOR HINGE WRENCH

2) Loosen the screw (A) and tap striker (B) using
plastic hammer to adjust the gap between rear end
surface of front door panel and front end surface of
rear door.

CAUTION:
Do not use an impact wrench. Welding area on
the striker nut plate is easily broken.

EB-00016

ST

EB-00017

(B)

(A)

EB-19

Front Sealing Cover

EXTERIOR BODY PANELS

5. Front Sealing Cover

A: REMOVAL

1) Disconnect the ground cable from the battery.
2) Remove the front door trim. <Ref. to EI-49, RE-
MOVAL, Door Trim.>
3) Remove the front speaker. <Ref. to ET-7, RE-
MOVAL, Front Speaker.>
4) Remove 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 part.

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:

3M 8626 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 part.

EB-00018