Subaru Outback (BR): Rear Door

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the rear door trim. <Ref. to EI-61, REAR DOOR, REMOVAL, Door Trim.>

3) Remove the rear door speaker assembly.

1. Remove the screws.
2. Disconnect the harness connector and remove the rear speaker assembly.

4) Remove the rear sealing cover.

CAUTION:

• Carefully remove the butyl tape. Excessive force will easily break the cover.
• If the sealing cover gets broken, replace it with a new part.

1. Remove the screw to remove the door trim bracket.
2. Carefully remove the butyl tape to remove the sealing cover.

5) Remove the door sash and rear door glass. <Ref. to GW-34, REMOVAL, Rear Door Glass.>

6) Remove the rear door regulator and motor assembly. <Ref. to GW-36, REMOVAL, Rear Regulator and Motor Assembly.>

7) Remove the rear door latch. <Ref. to SL-41, REMOVAL, Rear Door Latch and Door Lock Actuator Assembly.>

8) Remove the rear outer handle. <Ref. to SL-38, REMOVAL, Rear Outer Handle.>

9) Remove the rear door weather strip.

CAUTION: If the weather strip clip is removed with excessive force, the weather strip may be damaged. Be sure to use clip remover to remove.

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

11) Disconnect the rear door harness connectors.

1. Remove the grommet and pull out the rear door harness connector from inside the center pillar.
2. Disconnect the rear door harness connectors.

12) Before removing the door panel, make the following preparations.

1. Put a wooden block on a floor jack and place the jack under the rear door.
2. Support the rear door with the jack to protect it from damage.

CAUTION: Do not lift the door panel with a floor jack excessively. The door hinges may be damaged.

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

CAUTION: Door panels are heavy. When removing and installing them, always work in a team of two or more persons.

14) Remove the door hinge from vehicle.

B: INSTALLATION

1) Apply grease to the moving part of door hinges.

2) Put a wooden block on jack and place the rear door on that.

3) Temporarily install the rear door to upper hinge and lower hinge after adjusting the height by jack.

NOTE: When installing, make sure that a uniform clearance is created around the rear door panel.

4) Adjust the clearance around the rear door panel. <Ref. to EB-35, ADJUSTMENT, Rear Door.>

5) Tighten the bolts and nuts of door hinges and door checker.

Tightening torque: Refer to "COMPONENT" of "General Description". <Ref. to EB-5, REAR DOOR, COMPONENT, General Description.>

6) Install door internal parts in the reverse order of removal.

7) Connect the door harness connector, and install the center pillar lower trim.

C: ADJUSTMENT

Adjust the clearance around the rear door panel as follows.

1) Adjust the vertical and horizontal positions of rear door panel.

1. Loosen the body side bolts of upper and lower hinges.
2. Adjust the vertical and horizontal clearance of rear door panel.

2) Adjust the surface level gap between rear door panel and body.

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

1. Loosen the screws (A).
2. Tap the striker (B) using a plastic hammer to adjust the surface level gap between rear end of rear door panel and rear quarter.

Rear Sealing Cover

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the door trim assembly.

1. Open the cover and remove the screw.
2. Remove the clips in the order of (A) to (H) and remove the door trim assembly from the door panel.

CAUTION: When removing the door trim, be sure to remove the clips in the correct order. Forcibly removing clips may damage the door panel assembly.

NOTE: Insert a plastic clip remover into the slit at the bottom of the door trim, to lift the door trim.

3. Remove the cables (a) and (b) from the cable holder of inner remote.

4. Disconnect the harness connector and remove the door trim.

3) Remove the sealing cover.

CAUTION:

• Carefully remove the butyl tape. Excessive force will easily break the cover.
• If the sealing cover gets broken, replace it with a new part.

1. Remove the screw to remove the door trim bracket.
2. Carefully remove the butyl tape to remove the sealing cover.

B: INSTALLATION

CAUTION:

• If the sealing cover gets broken, replace it with a new part.
• Apply a butyl tape evenly.
• Attach the sealing cover, keeping it from becoming wrinkled.
• Breaks in the bead will allow water leakage and contamination.

1) Install each part 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 prevent any floating on surface.

Butyl tape:
3M8626 or equivalent

C: INSPECTION

If the sealing cover gets damaged, replace it with a new part.

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