Subaru Legacy III (2000-2003 year). Manual - part 991

EB-16

EXTERIOR BODY PANELS

REAR SEALING COVER

7. Rear Sealing Cover

A: REMOVAL

1) Remove rear door trim. <Ref. to EI-31, REMOV-
AL, Rear Door Trim.>
2) Remove rear speaker.  <Ref. to ET-8, REMOV-
AL, Rear Speaker.>

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

B: INSTALLATION

1) Install in the reverse order of removal.
2) When replacing sealing cover, use butyl tape.
3) Press sealer-applied area firmly to prevent any
floating on surface.

Butyl tape:

3M8626 or equivalent

NOTE:
• Apply a uniform bead of butyl tape.
• Attach sealing cover, keeping it from becoming
wrinkled.
• Breaks in the bead will allow water leakage and
contamination.

C: INSPECTION

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

EB-00058

EB-17

EXTERIOR BODY PANELS

TRUNK LID PANEL

8. Trunk Lid Panel

A: REMOVAL

1. TRUNK LID

1) Open trunk lid.
2) Disconnect trunk lid connector.
3) Loosen trunk lid mounting bolts to remove trunk
lid from hinges.

2. TORSION BAR

1) Open trunk lid.
2) Using special tool, remove torsion bar from
hinge link.
ST

927780000

REMOVER

CAUTION:
During removal and installation, carefully han-
dle torsion bar. It will generate reactive force.

3) Remove right/left torsion bars.

B: INSTALLATION

1. TRUNK LID

1) Install in the reverse order of removal.
2) Install trunk lid with uniform clearance.

2. TORSION BAR

1) Install in the reverse order of removal.
2) Apply grease to rotating area of hinges and mat-
ing surface of torsion bar.

Tightening torque:

14 N·m (1.4 kgf-m, 10 ft-lb)

EB-00066

EB-00067

ST

EB-18

EXTERIOR BODY PANELS

REAR GATE PANEL

9. Rear Gate Panel

A: REMOVAL

1. REAR GATE PANEL

1) Open rear gate.
2) Remove rear gate outer handle. <Ref. to SL-27,
REMOVAL, Rear Gate Outer Handle.>
3) Remove rear gate latch assembly. <Ref. to SL-
28, REMOVAL, Rear Gate Latch Assembly.>
4) Remove rear gate trim.  <Ref. to EI-44, REMOV-
AL, Rear Gate Trim.>
5) Remove rear gate key lock cylinders.  <Ref. to
SL-35, REAR GATE, REPLACEMENT, Key Lock
Cylinders.>
6) Remove rear finisher light assembly.  <Ref. to LI-
23, REMOVAL, Rear Finisher Light Assembly.>
7) Remove rear wiper. <Ref. to WW-16, REMOV-
AL, Rear Wiper Motor.>
8) Disconnect connectors of rear wiper, rear defog-
ger, and other lighting devices.
9) Disconnect washer hose.
10) Remove rubber duct (A) connection, and pull
out harness and washer hose from rear gate.

11) Using a support, support the rear gate while re-
moving gas stay mounting bolts.

NOTE:
When the rear gate is released, it may hit and dam-
age the body. To prevent this, place a shop cloth
between body and gate.
12) Loosen rear gate bolts to remove rear gate.

2. GAS STAY

1) Open rear gate. Using a jack to support the rear
gate.

CAUTION:
• After gas stay is removed, rear gate cannot
stay open. Supporting the rear gate with a jack,
remove the bolts.
• Do not damage piston rods and oil seals.
• Never disassemble cylinders: They contain
gas.
2) Loosen bolts to remove gas stay from rear gate.

B: INSTALLATION

1. REAR GATE PANEL

1) Install in the reverse order of removal.
2) Install rear gate panel with uniform clearance to
body.

2. GAS STAY

Install in the reverse order of removal.

Tightening torque:

Refer to COMPONENT in General Descrip-
tion. <Ref. to EB-7, REAR GATE PANEL, 
COMPONENT, General Description.>

EB-00068

( A )

EB-00069

EB-00069

EB-19

EXTERIOR BODY PANELS

REAR GATE PANEL

C: DISPOSAL

1. GAS STAY

1) Before opening a hole with a drill (A), put gas
stay (B) into a vinyl sack (C).

CAUTION:
Prevent the vinyl case from being caught by 
drill cutting edge
2) Lift body side slightly with piston rods fully ex-
tended, and secure body side on vise stand.
Drill a hole in 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 door
side, and bleed gas stay completely.

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

(A) Body side

(B) Door side

(1) Piston rod

(2) Cylinder

(3) Portion to be drilled

(4) 190 mm (7.48 in)

EB-00071

( A )

( B )

( C )

EB-00089

A

B

( 1 )

( 2 )

( 3 )

( 4 )