Subaru Outback (BR): Rear Gate Glass

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the rear gate trim. <Ref. to EI-160, REMOVAL, Rear Gate Trim.>

3) Remove the rear gate garnish. <Ref. to EI-164, REMOVAL, Rear Gate Garnish.>

4) Remove the rear wiper arm and rear wiper motor. <Ref. to WW-38, REMOVAL, Rear Wiper Motor.>

5) Disconnect the rear defogger connector and radio antenna connector.

6) Remove the rear gate glass in the same procedure as for windshield glass. <Ref. to GW-40, REMOVAL, Windshield Glass.>

B: INSTALLATION

NOTE: When applying adhesive and installing the dam rubber and molding, refer to Ag printing as a mark.

1. Molding edge
2. EPT sealer edge
3. Adhesive line
4. Spacer edge
5. Dam rubber edge (LH)
6. Dam rubber edge (RH)

1) Fabricate the cartridge nozzle tip as shown and set the sealant gun with the adhesive.

1. 10 mm (0.39 in)
2. 8 mm (0.31 in)
3. Sealant gun

2) Prepare and clean the adhesion surfaces of the glass and body using the same procedures as for the windshield glass. <Ref. to GW-43, INSTALLATION, Windshield Glass.>

3) Attach the dam rubber to the glass.

1. Locating pin
2. Dam rubber
3. Spacer
4. Holder
5. 15 mm (0.59 in)
6. EPT sealer

4) Install the molding to the glass.

CAUTION: Be careful to attach the molding so that the molding has no loose or undulating part.

1. Rear gate glass
2. Double-sided tape
3. Molding

5) Install the rear gate glass in the same procedure as for windshield glass. <Ref. to GW-43, INSTALLATION, Windshield Glass.>

1. Apply the primer to the adhesive surface of glass side and body side using sponge.
2. Apply adhesive to the glass end back surface.

1. Application of primer (glass side)
2. Application of primer (body side)
3. Adhesive
4. Molding
5. EPT sealer

3. Attach the clip to the rear gate glass holder.
4. Insert the glass locating pins in the rear gate panel holes and install the rear gate glass.
5. Lightly press the entire perimeter of rear gate glass for tight fit.
6. Make flush the adhesive surface jutted out using spatula.

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

NOTE:

• When door is opened/closed after glass is bonded, 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 instructions or instruction manual from the adhesive manufacturer.

7) Connect the rear defogger connector and radio antenna connector.

8) Install the rear wiper arm and rear wiper motor. <Ref. to WW-41, INSTALLATION, Rear Wiper Motor.>

9) Install the rear gate garnish. <Ref. to EI-166, INSTALLATION, Rear Gate Garnish.>

10) Install the rear gate trim. <Ref. to EI-161, INSTALLATION, Rear Gate Trim.>

11) Connect the battery ground terminal.

12) After curing of adhesive, pour the water on external 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.

Rear Window Glass

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Disconnect the rear defogger connector and radio antenna connector.

3) Remove the rear window glass in the same procedure as for windshield glass. <Ref. to GW-40, REMOVAL, Windshield Glass.>

B: INSTALLATION

1) Fabricate the cartridge nozzle tip as shown and set the sealant gun with the adhesive.

1. 10 mm (0.39 in)
2. 8 mm (0.31 in)
3. Sealant gun

2) Prepare and clean the adhesion surfaces of the glass and body using the same procedures as for the windshield glass. <Ref. to GW-43, INSTALLATION, Windshield Glass.>

3) Attach the dam rubber to the glass.

1. Locating pin
2. Dam rubber
3. 16 mm (0.63 in)
4. 1 mm (0.04 in)

4) Install the molding to the glass.

CAUTION: Be careful to attach the molding so that the molding has no loose or undulating part.

1. Align the molding (A) to the upper ends of the glass (C).
2. Install the molding from both corners of the upper edge toward the center.
3. Install the molding from both corners of the upper edge toward the lower side.
4. Firmly apply the double sided tape (B) of the molding evenly to the glass surface.

5) Install the rear glass in the same procedure as for windshield glass. <Ref. to GW-43, INSTALLATION, Windshield Glass.>

1. Apply the primer to the adhesive surface of glass side and body side using sponge.
2. Apply adhesive to the glass end back surface.

1. Application of primer (glass side)
2. Application of primer (body side)
3. Adhesive
4. Molding
5. Dam rubber

3. Insert the glass locating pins in the rear panel holes and install the rear glass.
4. Lightly press the entire perimeter of rear glass for tight fit.
5. Make flush the adhesive surface jutted out using spatula.

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

NOTE:

• When door is opened/closed after glass is bonded, 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 instructions or instruction manual from the adhesive manufacturer.

7) Connect the rear defogger connector and radio antenna connector.

8) Connect the battery ground terminal.

9) After curing of adhesive, pour the water on external 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.

Rear Window Defogger System

A: WIRING DIAGRAM

Refer to "Rear Defogger System" in the wiring diagram. <Ref. to WI-212, WIRING DIAGRAM, Rear Defogger System.>

B: INSPECTION

1. CHECK SYSTEM

NOTE: Rear window defogger system can be customized using the Subaru Select Monitor, when the customize setting {A/C ECM setting} of the body integrated unit is set to With.

2. CHECK WITH SUBARU SELECT MONITOR

CAUTION: Check whether the rear defogger operation mode setting is in initial setting or customize setting before performing inspection.

1) Check the input signal when the rear window defogger switch is operated using Subaru Select Monitor.

1. Prepare the Subaru Select Monitor. <Ref. to GW-7, PREPARATION TOOL, General Description.>
2. Turn the ignition switch to ON (engine OFF) and run the "PC application for Subaru Select Monitor".
3. On "System Selection Menu" display, select {Integ. unit mode}.
4. Select the {Rr defogger output} on {Current Data Display & Save}.
5. Check the displayed data (ON/OFF) by operating the rear window defogger switch.

2) Check the operation with rear window defogger switch ON.

• When customize setting is set as "Continuous", it is normal if the 15-minute operation and 2-minute stop repeats.
• When customize setting is "Normal", it is normal if the operation lasts for 15 minutes and then turns OFF.

3) When the operation in 2) above fails, replace the body integrated unit.

3. HEAT WIRE INSPECTION

CAUTION: Use a dry soft cloth to wipe off dirt on the glass along the heat wires with care not to damage the heat wires.

1) Prepare the following checking items.

• Liquid crystal thermograph sheet (Approximate Size: 300 × 300 mm (11.8 × 11.8 in) and thermal temperature: 35 - 40ºC (95 - 104ºF) )
• Aluminum foil

2) Turn the ignition switch to ON.

3) Turn the defogger switch to ON.

4) Push the liquid crystal thermograph sheet from the outside of the rear glass.

NOTE: Use the liquid crystal thermograph sheet every range it is separated with the separate line.

1. Liquid crystal thermograph sheet
2. Separate line

5) Determine the faulty heat wire by checking the color of the liquid crystal thermograph sheet.

NOTE:

• Check from the inside of the glass if the liquid crystal thermograph sheet does not change.
• The time for the color change may differ depends on the surface temperature of the glass.

6) Wrap a piece of aluminum foil around the tip of tester probe and press it against the heat wire with your finger.

1. Tester probe
2. Aluminum foil
3. Heat wire

7) To both ends of the section that has been found to include an open in the step 5), apply the tester positive (+) probe and the negative (-) probe.

8) Move the tester probe on the negative (-) side slowly along the heat wire. If voltage changes from zero while moving the tester probe, heat wire is open at the voltage change point.

9) Repair the heat wire that determines the place of the open circuit. <Ref. to GW-57, REPAIR, Rear Window Defogger System.>

C: REPAIR

1) Clean the broken portion with alcohol or white gasoline.

2) Mask both side of wire with masking tape.

3) Apply the conductive silver composition to the broken portion.

Conductive silver composition:
by Permatex
QUICK GRID

1. Broken portion
2. Masking tape
3. Broken wire
4. Conductive silver composition

4) Dry using a dryer after applying the composition.

5) After repair, check the wire.

Rear Quarter Glass

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the rear quarter trim. <Ref. to EI-114, OUTBACK MODEL, REMOVAL, Rear Quarter Trim.>

3) Remove the rear quarter glass in the same procedure as for windshield glass. <Ref. to GW-40, REMOVAL, Windshield Glass.>

B: INSTALLATION

1) Fabricate the cartridge nozzle tip as shown and set the sealant gun with the adhesive.

1. 10 mm (0.39 in)
2. 8 mm (0.31 in)
3. Sealant gun

2) Prepare and clean the adhesion surfaces of the glass and body using the same procedures as for the windshield glass. <Ref. to GW-43, INSTALLATION, Windshield Glass.>

3) Attach the dam rubber to the glass.

1. Fastener
2. Dam rubber
3. Clip
4. 8 mm (0.31 in)
5. 12 mm (0.47 in)
6. Molding

4) Install the rear quarter glass in the same procedure as for windshield glass. <Ref. to GW-43, INSTALLATION, Windshield Glass.>

1. Apply the primer to the adhesive surface of glass side and body side using sponge.
2. Apply adhesive to the glass end back surface.

NOTE: Use the molding terminal as a reference.

1. Application of primer (glass side)
2. Application of primer (body side)
3. Adhesive
4. Molding

3. Mount the fastener on the vehicle body.
4. Insert the clips in the side panel holes and install the rear quarter glass.
5. Lightly press the entire perimeter of rear quarter glass for tight fit.
6. Make flush the adhesive surface jutted out using spatula.

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

NOTE:

• When door is opened/closed after glass is bonded, 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 instructions or instruction manual from the adhesive manufacturer.

6) After curing of adhesive, pour the water on external 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.

7) Install the rear quarter trim. <Ref. to EI-119, INSTALLATION, Rear Quarter Trim.>

8) Connect the battery ground terminal.

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