Subaru Outback manuals

Subaru Outback: Front Door

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the front door trim. <Ref. to EI-60, FRONT DOOR, REMOVAL, Door Trim.>

3) Remove the outer mirror assembly. <Ref. to GW-28, REMOVAL, Outer Mirror Assembly.>

4) Remove the front door speaker assembly.

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

Subaru Outback. Exterior Body Panels

5) Remove the front sealing cover.

CAUTION:

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

Subaru Outback. Exterior Body Panels

6) Remove the door sash and front door glass. <Ref. to GW-17, REMOVAL, Front Door Glass.>

7) Remove the front door regulator and motor. <Ref. to GW-19, REMOVAL, Front Regulator and Motor Assembly.>

8) Remove the front door latch assembly. <Ref. to SL-34, REMOVAL, Front Door Latch and Door Lock Actuator Assembly.>

9) Remove the front outer handle. <Ref. to SL-31, REMOVAL, Front Outer Handle.>

10) Remove the front 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.

Subaru Outback. Exterior Body Panels

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

Subaru Outback. Exterior Body Panels

12) Release the claws, and then remove the side sill cover-front INN.

CAUTION: Do not pull with excessive force. Doing so may damage the claws of the side sill cover INN.

Subaru Outback. Exterior Body Panels

NOTE: To release the claws of the side sill cover INN, the following steps are recommended.

1. Take out the weather strip from under the side sill cover INN.

2. Turn over the floor mat and release the claw (C-C) by accessing from behind the side sill cover INN.

13) Remove the clip, and remove the side sill cover front.

Subaru Outback. Exterior Body Panels

14) Disconnect the connector of door harness from body harness.

Subaru Outback. Exterior Body Panels

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

Subaru Outback. Exterior Body Panels

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

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

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

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

Subaru Outback. Exterior Body Panels

17) Remove the door hinge from vehicle.

B: INSTALLATION

1) Remove the fender cover lower from fender panel.

2) Apply grease to the sliding area of door hinges, and install the door hinge to vehicle.

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

Subaru Outback. Exterior Body Panels

4) Temporarily install the front 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 front door panel.

5) Adjust the clearance around the front door panel. <Ref. to EB-28, ADJUSTMENT, Front Door.>

6) Install the fender cover lower.

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

Tightening torque: Refer to "COMPONENT" of "General Description". <Ref. to EB-4, FRONT DOOR, COMPONENT, General Description.>

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

9) Connect the door harness connector, and install the front pillar lower trim.

C: ADJUSTMENT

Adjust the clearance around the front door panel as follows.

Subaru Outback. Exterior Body Panels

Subaru Outback. Exterior Body Panels

NOTE: Common to sedan and OUTBACK models

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

Preparation tool: ST: WRENCH (925610000)

Subaru Outback. Exterior Body Panels

  1. Using ST, loosen the body side bolts of the upper and lower hinges.
  2. Adjust the vertical and horizontal clearance of front door panel.

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

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

Subaru Outback. Exterior Body Panels

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

Front Sealing Cover

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the gusset cover.

  1. Attach the protective tape (a) to the door trim.
  2. Release the clips and claws, then detach the gusset cover.

Subaru Outback. Exterior Body Panels

3) Remove the door trim assembly.

  1. Open the cover and remove the screw.
  2. Remove the clips in the order of (A) to (J) 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.

Subaru Outback. Exterior Body Panels

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

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

Subaru Outback. Exterior Body Panels

  1. Disconnect the harness connector and remove the door trim assembly.

4) Remove the sealing cover.

CAUTION:

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

Subaru Outback. Exterior Body Panels

B: INSTALLATION

CAUTION:

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.

READ NEXT:

 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. Remove the scr

 Door Sash Tape

A: REMOVAL 1. FRONT DOOR 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-60, FRONT DOOR, REMOVAL, Door Trim.> 3) Remove the outer mirror assembly. <R

 Trunk Lid

A: REMOVAL 1. TRUNK LID DAMPER STAY 1) Open the trunk lid. 2) Remove the trunk lid damper stay. Float the lock pin using a flat tip screwdriver, etc. and slide it. Remove the trunk lid damper stay

SEE MORE:

 Checking the oil level

Non-turbo models 1) Yellow handle Turbo models 1) Yellow handle Check the oil level monthly. 1. Park the vehicle on a level surface and stop the engine. 2. Pull out the level gauge, wipe it clean, and insert it again. 1) Upper level 2) Lower level 3. Pull out the level gauge again and

 Oil Temperature Sensor

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the cover (A) and clip (B) from air intake boot assembly. 3) Loosen the clamp (A) which connects the air intake boot assembly and air cleaner case. 4) Loosen the clamp (B) which connects the air intake boot assembly and throttle bo

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