Subaru Outback manuals

Subaru Outback: Rear Gate

A: REMOVAL

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

1. REAR GATE PANEL

1) Disconnect the ground cable from battery.

2) Remove the following parts. <Ref. to EI-164, REMOVAL, Rear Gate Garnish.>

3) Remove the high-mounted stop light assembly and rear washer nozzle. <Ref. to WW-43, REMOVAL, Rear Washer.>

4) Remove the rear finisher light assembly. <Ref. to LI-54, OUTBACK MODEL, REMOVAL, Rear Finisher Light Assembly.>

5) Remove the rearview camera assembly. <Ref. to ET-46, OUTBACK MODEL, REMOVAL, Rearview Camera System.>

6) Remove the rear gate latch & actuator assembly. <Ref. to SL-47, REMOVAL, Rear Gate Latch and Actuator Assembly.>

7) Remove the clips, and then remove the rear gate drip rubber.

Subaru Outback. Exterior Body Panels

8) Disconnect the rubber duct (A) connection.

Subaru Outback. Exterior Body Panels

9) Pull out the harnesses and washer hose from the rear gate.

10) Remove harness clip of each connector from the rear gate panel.

11) Before removing the rear gate damper stay, prevent the rear gate from closing using prop or the like.

CAUTION: If the prop comes off, operators may get injured and vehicle may get damaged. Make sure to support the rear gate with secure material to prevent injury or damage.

Subaru Outback. Exterior Body Panels

12) Remove the mounting bolt of rear gate damper stay.

Subaru Outback. Exterior Body Panels

13) Remove the rear gate hinge bolt, and remove the rear gate panel.

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

Subaru Outback. Exterior Body Panels

14) Remove the rear gate hinge from the vehicle.

2. REAR GATE DAMPER STAY

CAUTION:

1) Before removing the rear gate damper stay, prevent the rear gate from closing using prop or the like.

CAUTION: If the prop comes off, operators may get injured and vehicle may get damaged. Make sure to support the rear gate with secure material to prevent injury or damage.

Subaru Outback. Exterior Body Panels

2) Remove the rear gate damper stay by removing mounting bolts.

Subaru Outback. Exterior Body Panels

B: INSTALLATION

1. REAR GATE PANEL

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

1) Install the rear gate hinges to the vehicle body.

2) Temporarily install the rear gate panel to the rear gate hinges.

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

3) Adjust the clearance around the rear gate panel. <Ref. to EB-52, ADJUSTMENT, Rear Gate.>

4) Tighten the rear gate hinge bolts.

Tightening torque: 25 N*m (2.55 kgf-m, 18.4 ft-lb)

5) Install each part in the reverse order of removal.

Tightening torque:
Rear gate parts: <Ref. to EB-7, REAR GATE, COMPONENT, General Description.>
Rear gate garnish: 4.5 N*m (0.46 kgf-m, 3.3 ft-lb)
Rear wiper motor & rear wiper arm: <Ref. to WW-4, REAR WIPER, COMPONENT, General Description.>

2. REAR GATE DAMPER STAY

CAUTION:

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

1) Prevent the rear gate from closing using prop or the like.

CAUTION: If the prop comes off, operators may get injured and vehicle may get damaged. Make sure to support the rear gate with secure material to prevent injury or damage.

Subaru Outback. Exterior Body Panels

2) Install each part in the reverse order of removal.

Tightening torque: Refer to "COMPONENT" of "General Description". <Ref. to EB-7, REAR GATE, COMPONENT, General Description.>

C: ADJUSTMENT

Adjust the clearance around the rear gate panel as follows.

Subaru Outback. Exterior Body Panels

1) Align the rear gate panel longitudinal and lateral position.

Subaru Outback. Exterior Body Panels

  1. Loosen the hinge attaching bolts.
  2. Align the rear gate panel longitudinal and lateral panel dimension.

Tightening torque: 25 N*m (2.55 kgf-m, 18.4 ft-lb)

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

Subaru Outback. Exterior Body Panels

  1. Loosen the bolt.
  2. Tap striker using plastic hammer to adjust the gap between rear gate panel and body surface.

Tightening torque: 25 N*m (2.55 kgf-m, 18.4 ft-lb)

D: DISPOSAL

1. REAR GATE DAMPER STAY

CAUTION: Gas is colorless, odorless, and harmless. However, gas pressure may spray cutting powder or oil. Be sure to wear dust-resistant goggles.

1) Cover with a vinyl sack as shown in the figure.

Subaru Outback. Exterior Body Panels

  1. Rear gate damper stay
  2. Vinyl sack

NOTE: Prevent the vinyl sack from being caught by drill cutting edge.

2) Lift the body side slightly with piston rods fully extended, and secure the body side with vise.

Drill a hole of 2 to 3 mm (0.08 to 0.12 in) diameter at a point 10 to 200 mm (0.39 to 7.87 in) from the body side, and bleed the gas in the rear gate damper stay completely.

Subaru Outback. Exterior Body Panels

  1. Door side
  2. Body side
  3. 190 mm (7.48 in)
  4. 10 mm (0.39 in)
  5. Piston rod
  6. Cylinder
  7. Portion to be drilled

Protector Tape

A: INSTALLATION

Apply the protector tape by the following steps.

1. REAR DOOR PROTECTOR (OUTBACK MODEL)

Subaru Outback. Exterior Body Panels

  1. Rear door garnish end
  2. Rear door panel end
  1. Align the application paper to the rear door garnish terminal.
  2. Align the protector tape to the end of rounded corner.

Subaru Outback. Exterior Body Panels

  1. Rear door garnish end
  2. Rear door panel end
  1. Align the application paper to the rear door garnish terminal.
  2. Align the protector tape to the end of rounded corner.

1) Clean the area around applying position to remove any foreign objects on body.

2) Detach the backing paper and apply the protector tape after positioning it correctly.

3) Detach the backing papers, and moisten the applying area and the backside of protector tape by spraying liquid (mild detergent solution at 3% concentration).

4) Apply the protector tape to the vehicle body.

CAUTION: Remove the water or air bubbles out of the protector tape by using the plastic or rubber spatula.

5) Detach the application tape and temporary retention tape.

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