SUBARU LEGACY 1999 Service Repair Manual

12. Front Grille
A: REMOVAL AND INSTALLATION
1) Remove four upper clips from body panel. To
facilitate removal, press portion shown in figure
using screwdriver.
B5M0294A
2) Pull front grille to detach it from two lower clips.
(Two lower clips remain on headlight.)
3) Installation is in the reverse order of removal.
NOTE:
Attach all clips to grille. Align them with clip hole in
body and push them into place.
13. Door Mirror
A: REMOVAL AND INSTALLATION
1) Remove the gusset cover.
B6M0146
2) Remove inner remote control switch cover.
B5M0296
3) Remove front door trim.
B5M0297
4) Remove front door trim.
55
[W13A0]5-1SERVICE PROCEDURE
13. Door Mirror

5) Disconnect the door mirror connector.
6) Remove the door mirror installation screws.
B5M0298A
7) Installation is in the reverse order of removal.
14. Side Protector
A: REMOVAL AND INSTALLATION
Side protector consists of three parts; front fender,
front door and rear door.
B5M0411A
1. SIDE PROTECTOR FRONT FENDER
PORTION
1) Remove bracket which secures mud guard to
front fender.
B5M0285A
2) Remove mud guard. <Ref. to 5-1 [W9A2].>
NOTE:
Detach the rear part of mud guard as required for
the procedure. It is not necessary to remove the
entire mud guard.
3) Use pliers to remove a clip from inside front
fender. Remove it from vehicle body but keep it
with side protector.
4) Installation is in the reverse order of removal.
56
5-1[W14A0]SERVICE PROCEDURE
14. Side Protector

5) Disconnect the door mirror connector.
6) Remove the door mirror installation screws.
B5M0298A
7) Installation is in the reverse order of removal.
14. Side Protector
A: REMOVAL AND INSTALLATION
Side protector consists of three parts; front fender,
front door and rear door.
B5M0411A
1. SIDE PROTECTOR FRONT FENDER
PORTION
1) Remove bracket which secures mud guard to
front fender.
B5M0285A
2) Remove mud guard. <Ref. to 5-1 [W9A2].>
NOTE:
Detach the rear part of mud guard as required for
the procedure. It is not necessary to remove the
entire mud guard.
3) Use pliers to remove a clip from inside front
fender. Remove it from vehicle body but keep it
with side protector.
4) Installation is in the reverse order of removal.
56
5-1[W14A0]SERVICE PROCEDURE
14. Side Protector

CAUTION:
Insert clips firmly and carefully by hand. To
avoid damaging clips, do not forcefully push or
hit clips.
2. SIDE PROTECTOR FRONT DOOR AND
REAR DOOR PORTIONS
1) Remove trim panel. <Ref. to 5-2 [W2A2].>
2) Use pliers to remove clips from inside of doors.
Remove them from vehicle body but keep them
with side protector.
NOTE:
Front door portion has five clips, rear door portion
has four clips.
3) Installation is in the reverse order of removal.
CAUTION:
Insert clips firmly and carefully by hand. To
avoid damaging clips, do not forcefully push or
hit clips.
NOTE:
To install side protector front door and rear door
portions, insert the first clip into the base hole [9
mm (0.35 in) dia.], and then insert other clips.
15. Roof Rail
A: REMOVAL AND INSTALLATION
1) Remove roof trim, rear quarter trim, pillar trim,
etc. <Ref. to 5-3 [W5A0].>
2) Remove flange bolts.
3) Remove flange nuts.
4) Remove roof rail.
B5M0304
5) Installation is in the reverse order of removal.
CAUTION:
To prevent deformation, be sure to install roof
rail in steps 4), 3), 2) and 1), in that order.
57
[W15A0]5-1SERVICE PROCEDURE
15. Roof Rail

CAUTION:
Insert clips firmly and carefully by hand. To
avoid damaging clips, do not forcefully push or
hit clips.
2. SIDE PROTECTOR FRONT DOOR AND
REAR DOOR PORTIONS
1) Remove trim panel. <Ref. to 5-2 [W2A2].>
2) Use pliers to remove clips from inside of doors.
Remove them from vehicle body but keep them
with side protector.
NOTE:
Front door portion has five clips, rear door portion
has four clips.
3) Installation is in the reverse order of removal.
CAUTION:
Insert clips firmly and carefully by hand. To
avoid damaging clips, do not forcefully push or
hit clips.
NOTE:
To install side protector front door and rear door
portions, insert the first clip into the base hole [9
mm (0.35 in) dia.], and then insert other clips.
15. Roof Rail
A: REMOVAL AND INSTALLATION
1) Remove roof trim, rear quarter trim, pillar trim,
etc. <Ref. to 5-3 [W5A0].>
2) Remove flange bolts.
3) Remove flange nuts.
4) Remove roof rail.
B5M0304
5) Installation is in the reverse order of removal.
CAUTION:
To prevent deformation, be sure to install roof
rail in steps 4), 3), 2) and 1), in that order.
57
[W15A0]5-1SERVICE PROCEDURE
15. Roof Rail

16. Sunroof
A: REMOVAL AND INSTALLATION
1. SEDAN AND WAGON REAR (EXCEPT
OUTBACK)
1) Glass lid assembly:
(1) Completely open sun shade. (Push it back
far.)
(2) Remove a clip and detach guide rail cover.
(3) Remove six nuts from the left and right lid
bracket.
(4) Working inside, slightly raise glass lid
assembly until it is disengaged from lid bracket.
B5M0307A
(5) Hold both ends of glass lid assembly and
remove it at an angle.
(6) Installation is in the reverse order of
removal.
2) Sunroof motor and relay:
(1) Remove center pillar trim upper. <Ref. to
5-3 [W5A3].>
(2) Remove front pillar trim upper. <Ref. to 5-3
[W5A4].>
(3) Remove assist grip on left side.
(4) Remove sunvisor with hook.
(5) Remove sunroof switch.
(6) Remove rearview mirror.
(7) While rolling up roof trim, disconnect har-
ness clips and connector.
(8) While rolling up roof trim, remove spot lamp
bracket and sunroof motor.
(9) Installation is in the reverse order of
removal.
B5M0308B
3) Sunroof frame:
(1) Remove sunroof switch, center and rear
room lamps.
(2) Remove roof trim, rear quarter trim, pillar
trim, etc. <Ref. to 5-3 [W5A0].>
(3) Remove glass lid assembly.
(4) Remove two harness support clips.
B5M0310A
(5) Disconnect harness clips and connector of
sunroof motor.
(6) Disconnect front and rear drain tubes.
CAUTION:
When installing drain tube, insert it securely
into drain pipe.
Length A:
15 mm (0.59 in) or more
G5M0205
(7) Remove eight nuts.
B5M0312
58
5-1[W16A1]SERVICE PROCEDURE
16. Sunroof

(8) Remove set bracket mounting bolts.
(9) Remove sunroof frame.
B5M0382A
(10) Installation is in the reverse order of
removal.
2. WAGON FRONT (OUTBACK)
1) Sunroof panel:
(1) Tilt up the front sunroof (Most upper posi-
tion).
(2) Disconnect ground cable from battery.
(3) Remove sunroof switch then remove two
bolts.
(4) Remove cover then remove two nuts from
tilt up assembly.
(5) Take off the sunroof panel from body.
B5M0482A
(6) Installation is in the reverse order of
removal.
CAUTION:
When installing sunroof panel, ensure not to
pinch its panel end lip.
B5M0483A
2) Sunroof motor assembly:
(1) Remove sunroof panel. <Ref. to 5-1
[W16A2].>
(2) Remove motor cover.
(3) Disconnect connector then remove sunroof
motor assembly.
B5M0484A
(4) Installation is in the reverse order of
removal.
3) Sunroof flame:
(1) Remove sunroof panel. <Ref. to 5-1
[W16A2].>
(2) Remove roof trim panel. <Ref. to 5-3
[W5A9].>
(3) Remove sunroof flame.
NOTE:
To facilitate installation, leave the two front mount-
ing bolts on the body.
B5M0311A
(4) Installation is in the reverse order of
removal.
59
[W16A2]5-1SERVICE PROCEDURE
16. Sunroof

4) Tilt up assembly:
(1) Remove sunroof flame. <Ref. to 5-1
[W16A2].>
(2) Remove tilt up assembly.
B5M0485A
(3) Installation is in the reverse order of
removal.
B: ADJUSTMENT
1. SEDAN AND WAGON REAR (EXCEPT
OUTBACK)
1) Alignment of height between glass lid assembly
and roof panel:
(1) Remove guide rail cover.
(2) Loosen nuts and adjust height by adding
(Max: two pieces) and extracting (Max: one
piece) shim(s) (Standard: one piece) between
glass lid assembly and lid bracket.
Difference in height between glass lid assem-
bly and roof panel:
0
±0.5 mm (0±0.020 in)
B5M0314B
B5M0315B
2) Alignment of glass lid assembly with roof panel:
(1) Remove guide rail cover.
(2) Loosen nuts and move glass lid assembly
to either side to adjust front, rear, right, and left
side partitions.
Partition clearance:
7.0
±0.5 mm (0.276±0.020 in)
B5M0316A
3) Checking for movement of glass lid assembly
itself:
(1) Before installing sunroof motor, check glass
lid assembly for movement.
(2) Place a cloth on glass lid assembly and sun
shade, and attach a spring scale to glass lid
assembly edge using the cloth.
B5M0317
(3) Pull spring scale to measure force required
to move glass lid assembly.
Force required to move glass lid assembly
and sun shade trim:
Less than 196 N (20 kg, 44 lb)
Considerable effort is required to start glass lid
assembly moving, so take scale reading while
glass lid assembly is moving smoothly.
(4) If force required exceeds specifications,
check the following points:
IGlass lid assembly, sun shade and deflector and
guide rail assembly for improper installation
ICable for seizure
60
5-1[W16B1]SERVICE PROCEDURE
16. Sunroof

2. WAGON FRONT (OUTBACK)
1) Alignment of height between sunroof panel and
roof panel
Loosen sunroof panel installation bolts and nuts
then adjust height by adding (Max: two pieces) and
extracting (Max: one piece) shim(s) (Standard: one
piece) between sunroof panel hinge and body.
Difference in height between sunroof panel
and roof panel:
0
±1.0 mm (0±0.039 in)
B5M0486A
2) Alignment of partition clearance
Loosen sunroof panel installation bolts and nuts
then move glass to either side to adjust front, rear,
right, and left side partitions.
Partition clearance:
1
±1.0 mm (0.04±0.039 in)
B5M0487A
17. Undercover
A: REMOVAL AND INSTALLATION
1) Remove undercover mounting bolts.
B5M0412A
2) Installation is in the reverse order of removal.
NOTE:
Undercover is bolted along with mud guard.
61
[W17A0]5-1SERVICE PROCEDURE
17. Undercover

2. WAGON FRONT (OUTBACK)
1) Alignment of height between sunroof panel and
roof panel
Loosen sunroof panel installation bolts and nuts
then adjust height by adding (Max: two pieces) and
extracting (Max: one piece) shim(s) (Standard: one
piece) between sunroof panel hinge and body.
Difference in height between sunroof panel
and roof panel:
0
±1.0 mm (0±0.039 in)
B5M0486A
2) Alignment of partition clearance
Loosen sunroof panel installation bolts and nuts
then move glass to either side to adjust front, rear,
right, and left side partitions.
Partition clearance:
1
±1.0 mm (0.04±0.039 in)
B5M0487A
17. Undercover
A: REMOVAL AND INSTALLATION
1) Remove undercover mounting bolts.
B5M0412A
2) Installation is in the reverse order of removal.
NOTE:
Undercover is bolted along with mud guard.
61
[W17A0]5-1SERVICE PROCEDURE
17. Undercover