Subaru Outback manuals

Subaru Outback: Windshield Glass

A: REMOVAL

1. USING WINDSHIELD GLASS KNIFE

1) Disconnect the ground cable from battery. (Models with wiper deicer)

2) Remove the front pillar trim. <Ref. to EI-102, REMOVAL, Upper Inner Trim.>

3) Disconnect the wiper deicer connector. (Models with wiper deicer)

4) Remove the cowl panel. <Ref. to EI-32, REMOVAL, Cowl Panel.>

5) Remove the molding from the glass and tape the body side of the circumference of windshield glass for protection.

Subaru Outback. Glass/Windows/Mirrors

  1. Molding
  2. Windshield glass
  3. Body panel
  4. Protective tape
  5. Adhesive

6) Remove the windshield glass.

  1. Apply sufficient amount of soapy water to the adhesive part and insert the windshield glass knife.
  2. While holding the knife edge and windshield glass edge at a right angle, move the windshield glass knife parallel to the windshield glass edge along the surface and edge of windshield glass to cut the adhesive.

CAUTION:

Subaru Outback. Glass/Windows/Mirrors

  1. Windshield glass knife
  2. Protective tape
  3. Adhesive
  4. Windshield glass
  5. Body panel
  1. Disconnect the locating pin and remove the windshield glass.

NOTE: The locating pins are bonded to the corners of glass. Use piano wire to disconnect the pins.

Subaru Outback. Glass/Windows/Mirrors

  1. Locating pin
  2. Body panel
  3. Windshield glass

2. USING PIANO WIRE

CAUTION:

1) Disconnect the ground cable from battery. (Models with wiper deicer)

2) Remove the front pillar trim. <Ref. to EI-102, REMOVAL, Upper Inner Trim.>

3) Disconnect the wiper deicer connector. (Models with wiper deicer)

4) Remove the cowl panel. <Ref. to EI-32, REMOVAL, Cowl Panel.>

5) Remove the molding from the glass and tape the body side of the circumference of windshield glass for protection.

Subaru Outback. Glass/Windows/Mirrors

  1. Molding
  2. Windshield glass
  3. Body panel
  4. Protective tape
  5. Adhesive

6) Remove the windshield glass.

  1. Using a drill, make a hole in the adhesive part.
  2. Pass the piano wire through the hole, and pull the wire ends alternately to cut off the adhesive part and locating pin.

CAUTION: Attach a piece of wood to both piano wire ends.

Subaru Outback. Glass/Windows/Mirrors

  1. Piano wire
  2. Windshield glass
  3. Adhesive
  4. Body panel
  5. Protective tape

B: INSTALLATION

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

Subaru Outback. Glass/Windows/Mirrors

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

2) Remove the adhesive layer on the body using cutter knife to obtain smooth face of 2 mm (0.08 in) thick.

CAUTION:

Subaru Outback. Glass/Windows/Mirrors

  1. Adhesive
  2. Body panel
  3. 2 mm (0.08 in)

3) Clean the glass and body with alcohol or white gasoline to eliminate cutting powder, dust and dirt completely.

4) Attach the dam rubber to the glass.

Subaru Outback. Glass/Windows/Mirrors

  1. Locating pin
  2. Dam rubber
  3. 15 mm (0.59 in)
  4. 13.5 mm (0.53 in)
  5. 23.5 mm (0.92 in)

5) Install the molding to the glass.

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

Subaru Outback. Glass/Windows/Mirrors

  1. Align the molding (A) with both ends of the upper edge of the windshield 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.

NOTE: Change the molding installation width within the gradual change range (E) based on the curve end point on the upper end of side area (D).

  1. Firmly apply the double sided tape (B) of the molding evenly to the glass surface.

6) Install the windshield glass.

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

Glass primer:
Dow Automotive's
ESSEX U-401, U-402 or equivalent

Painted surface primer:
Dow Automotive's
ESSEX U-413 or equivalent

NOTE:

  1. Apply adhesive to the glass end back surface.

Adhesive:
Dow Automotive's
ESSEX U-400HV or equivalent

Subaru Outback. Glass/Windows/Mirrors

  1. Application of primer (glass side)
  2. Application of primer (body side)
  3. Adhesive
  4. Molding
  5. Dam rubber
  1. Fit the locating pins to vehicle body using suction rubber cup to install the windshield glass.

Subaru Outback. Glass/Windows/Mirrors

  1. Lightly press the entire perimeter of windshield glass for tight fit.
  2. Make flush the adhesive surface jutted out using spatula.

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

NOTE:

8) 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.

9) Install the cowl panel. <Ref. to EI-34, INSTALLATION, Cowl Panel.>

10) Connect the wiper deicer connector. (Models with wiper deicer)

11) Install the front pillar trim. <Ref. to EI-107, INSTALLATION, Upper Inner Trim.>

12) Connect the battery ground terminal. (Models with wiper deicer)

READ NEXT:

 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, R

 Rearview Mirror

A: REMOVAL CAUTION: Be careful not to damage the mirror surface and windshield glass. 1) Remove the TORX bolt, and then slide the rear view mirror to remove. Preparation tool: TORX T20 2) When the mi

 Instrumentation/Driver Info

General Description A: SPECIFICATION Combination meter Clock B: CAUTION Before disassembling or reassembling parts, always disconnect the battery ground cable from battery. When replacing

SEE MORE:

 Front Strut

A: REMOVAL 1) Lift up the vehicle, and then remove the front wheels. 2) Remove the front strut. Place an alignment mark on the camber adjusting bolt and strut. Remove the brake hose bracket. Remove the ABS wheel speed sensor harness. Remove the two bolts securing the front axle housing t

 Center console box (rear)

The center console box has a two-layer structure consisting of an upper compartment and a lower compartment. Upper compartment 1) Upper compartment lock release Pull up the upper compartment lock release to open the upper compartment. Lower compartment 1) Lower compartment lock release

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