sunroof SUBARU FORESTER 1999 Service Repair Manual

6. Sunroof
S5M0290A
(1) Glass lid
(2) Rear drain ASSY
(3) Frame ASSY
(4) Motor ASSY
(5) Drive unit
(6) Drain tube(7) Harness
(8) Sunshade
(9) Garnish
(10) Frame bracket
(11) Cover
(12) Deflector(13) Shim
Tightening torque: N´m (kg-m, ft-lb)
T:
7.4±2.0 (0.75±0.2, 5.4±1.4)
27
[C600]5-1COMPONENT PARTS
6. Sunroof

15. Sunroof
A: REMOVAL AND INSTALLATION
1. GLASS LID
1) Completely close glass lid and open sunshade.
2) Detach the four covers (A) and then remove
eight nuts.
S5M0292A
3) Carefully remove glass lid.
4) Install in the reverse order of removal.
2. SUNROOF FRAME
1) Remove roof trim.
2) Remove glass lid.
3) Disconnect the four drain tubes (A) from sun-
roof frame.
4) Disconnect sunroof harness connector.
5) Remove installation bolts and nuts and then
detach sunroof frame.
S5M0293A
6) Install in the reverse order of removal.
CAUTION:
Be careful not to snag the harness.
NOTE:
IMake sure to connect harness connector.IWhen installing drain tube, insert it securely into
drain pipe.
Length A:
15 mm (0.59 in) or more
G5M0205
B: ADJUSTMENT
1. ALIGNMENT OF HEIGHT BETWEEN
SUNROOF GLASS LID AND ROOF PANEL
Loosen sunroof glass lid installation nuts and then
adjust height by adding (max: two pieces) and
extracting (max: one piece) shim(s) (A) (standard:
one piece) between sunroof glass lid (B) and roof
panel (C).
Difference in height between sunroof glass lid
and roof panel:
0
±1.0 mm (0±0.039 in)
S5M0294B
42
5-1[W15A1]SERVICE PROCEDURE
15. Sunroof

2. CHECKING FOR MOVEMENT OF
SUNROOF PANEL ITSELF
1) Place a cloth on sunshade, and attach a spring
scale to sunshade edge using the cloth.
S5M0295
2) Pull spring scale to measure force required to
move sunshade.
Force required to move sunshade:
Less than 24.5
±4.9 N (2.5±0.5 kg, 5.5±1.1
lb)
NOTE:
Considerable effort is required to start sunshade
moving, so take scale reading while sunroof panel
is moving smoothly.
3) If force required exceeds specifications, check
the sunroof glass lid, sunshade and deflector, and
guide rail assembly for improper installation.
16. Crossbar
A: REMOVAL
1) Loosen and remove TORX bolt T30 from the
top of each crossbar end support, and then remove
inner clamp.
S5M0330A
(1) TORX bolt T30
(2) End support
(3) Inner clamp
(4) Roof rail
2) Remove crossbar.
NOTE:
When removing the front crossbar from the roof
rail, first move the front crossbar to the center of
the roof rail.
B: INSTALLATION
1. FRONT CROSSBAR
NOTE:
Front crossbar has ªMAXIMUM LOAD ROOF
RACK-150LBS. EVENLY DISTRIBUTED ROOF
SURFACE-100LBS. EVENLY DISTRIBUTEDº
label on LH side.
1) Loosen and remove TORX bolt T30 from the
top of each crossbar end support, and then remove
the inner clamp.
43
[W16B1]5-1SERVICE PROCEDURE
16. Crossbar

2.
SUNROOF
1\)
scale
S5M0295
2\)
move
ForceLess
\2614.9\2610.5\2611.1
lb\)
NOTE:
Considerable
moving,
is
3\)
the
guide
16.
A:
1\)
top
inner
S5M0330A
\(1\)
\(2\)
\(3\)
\(4\)
2\)
NOTE:
When
rail,
the
B:
1.
NOTE:
Front
RACK-150LBS.
SURF
label
1\)
top
the
43
[W16B1]5-1SER
16.

1. Sunroof
Entry of water into compartment(1) Check roof panel and sunroof glass lid for improper or
poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
Booming noise(1) Check sunroof glass lid and roof panel for improper clear-
ance.
(2) Check sunshade and roof trim for improper clearance.
Abnormal motor noise(1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cable for wear.
(4) Check cable pipe for deformities.
Failure of sunroof to operate
(Motor operates properly.)(1) Check guide rail for foreign particles.
(2) Check guide rail for improper installation.
(3) Check parts for mutual interference.
(4) Check cable slider for improper clinching.
(5) Check cable for improper installation.
(6) Check clutch adjustment nut for improper tightness.
Motor does not rotate or rotates improperly.
(Use sunroof wrench to check operation.)(1) Check fuse for blowout.
(2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check relay for improper operation.
(5) Check poor grounding system.
(6) Check cords for discontinuity and terminals for poor con-
nections.
(7) Check limit switch for improper operation.
45
[K100]5-1DIAGNOSTICS
1. Sunroof

3. FLOOR SECTION
1) Removal order of floor mat:
(1) Remove front seats.
(2) Remove rear seat cushion. [W2A1].>
(3) Remove console box, depending on the
specifications.
(4) Remove front pillar lower trim panel. to 5-3 [W5A1].>
(5) Remove center pillar lower trim panel. to 5-3 [W5A1].>
(6) Remove side sill cover. [W5A1].>
(7) Remove clips from floor mat.
NOTE:
When pulling out edge, do not pull mat alone; pull
mat together with edge. Pry off two steel clips on
side sill front cover and one on side sill rear cover
using screwdriver.
(8) Remove mat hook.
(9) Remove mat from toe board area.
(10) Remove mat from rear heater duct.
(11) Roll mat, and take it out of opened rear
door.
S5M0240
(12) Install in the reverse order of removal.
NOTE:
ISecure mat firmly with hook and velcro tape.
IInsert mat edge firmly into the groove of side sill
cover.
2) Removal order of rear floor box:(1) Remove clips and then detach rear floor
boxes.
S5M0241
(2) Install in the reverse order of removal.
4. ROOF TRIM
1) Remove head console.
S5M0243
2) Remove sunvisor and assist rail.
3) Remove front pillar upper trim and center pillar
upper trim , rear quarter
upper trim and rear rail trim.
4) Detach sunroof garnish (A). (Sunroof equipped
model)
S5M0305B
5) Using ST, remove clips.
ST 925580000 PULLER
14
5-3[W5A3]SERVICE PROCEDURE
5. Inner Trim Panel