sunroof SUBARU LEGACY 1995 Service Repair Manual

6. Sunroof
B5M0370A
1Glass lid ASSY

2Deflector and guide rail ASSY

3Guide rail cover

4Frame ASSY

5Motor ASSY

6Drain ASSY

7Sun shade

8Drain tube

9Garnish

10Set bracket
Tightening torque: N⋅m (kg-m, ft-lb)
T: 7.4±2.0 (0.75±0.2, 5.4±1.4)
28
5-1COMPONENT PARTS
6. Sunroof

B5M0304
15. Roof Rack (Wagon only, if
equipped)
A: REMOVAL
1) Remove roof trim, rear quarter trim, pillar trim, etc.

2) Remove flange bolts.
3) Remove flange nuts.
4) Remove roof rail.
B: INSTALLATION
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.
B5M0307A
16. Sunroof
A: REMOVAL
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.
5) Hold both ends of glass lid assembly and remove it at
an angle.
B5M0308B
2. SUNROOF MOTOR AND RELAY
1) Remove center pillar trim upper.
2) Remove front pillar trim upper.
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 harness clips and
connector.
8) While rolling up roof trim, remove spot lamp bracket and
sunroof motor.
51
5-1SERVICE PROCEDURE
15. Roof Rack (Wagon only, if equipped) - 16. Sunroof

B5M0304
15. Roof Rack (Wagon only, if
equipped)
A: REMOVAL
1) Remove roof trim, rear quarter trim, pillar trim, etc.

2) Remove flange bolts.
3) Remove flange nuts.
4) Remove roof rail.
B: INSTALLATION
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.
B5M0307A
16. Sunroof
A: REMOVAL
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.
5) Hold both ends of glass lid assembly and remove it at
an angle.
B5M0308B
2. SUNROOF MOTOR AND RELAY
1) Remove center pillar trim upper.
2) Remove front pillar trim upper.
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 harness clips and
connector.
8) While rolling up roof trim, remove spot lamp bracket and
sunroof motor.
51
5-1SERVICE PROCEDURE
15. Roof Rack (Wagon only, if equipped) - 16. Sunroof

B5M0310A
3. SUNROOF FRAME
1) Remove sunroof switch, center and rear room lamps.
2) Remove roof trim, rear quarter trim, pillar trim, etc.

3) Remove glass lid assembly.
4) Remove two harness support clips.
G5M0205
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
B5M0312
7) Remove eight nuts.
B5M0382A
8) Remove set bracket mounting bolts.
9) Remove sunroof frame.
52
5-1SERVICE PROCEDURE
16. Sunroof

B: INSTALLATION
Installation is in the reverse order of removal.
B5M0314B
B5M0315B
C: ADJUSTMENTS
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 assembly and
roof panel:
0±0.5 mm (0±0.020 in)
B5M0316A
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)
53
5-1SERVICE PROCEDURE
16. Sunroof

B5M0317
3. CHECKING FOR MOVEMENT OF GLASS LID
ASSEMBLY ITSELF
1) Before installing sunroof motor, check glass lid assem-
bly 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.
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 fol-
lowing points:

Glass lid assembly, sun shade and deflector and guide
rail assembly for improper installation

Cable for seizure
54
5-1SERVICE PROCEDURE
16. Sunroof

1. Sunroof
Entry of water into compartment
1Check roof panel and glass lid assembly for improper or poor
sealing.

2Check drain tube for clogging.

3Check sunroof frame seal and body for improper fit.
Booming noise
1Check glass lid assembly and roof panel for improper clear-
ance.

2Check sun shade and roof trim for improper clearance.
Abnormal motor noise
1Check motor for looseness.

2Check gears and bearings for wear.

3Check cable for wear.

4Check cable pipe for deformities.
Failure of sunroof to operate
(Motor operates properly.)
1Check guide rail for foreign particles.

2Check guide rail for improper installation.

3Check parts for mutual interference.

4Check cable slider for improper clinching.

5Check cable for improper installation.

6Check clutch adjustment nut for improper tightness.
Motor does not rotate or rotates improperly.
(Use sunroof wrench to check operation.)
1Check fuse for blowout.

2Check switch for improper function.

3Check motor for incorrect terminal voltage.

4Check relay for improper operation.

5Check poor grounding system.

6Check cords for discontinuity and terminals for poor connec-
tions.

7Check limit switch for improper operation.
55
5-1DIAGNOSTICS
1. Sunroof

19. Sunroof
A: REMOVAL AND INSTALLATION
1. SUNROOF AND SUNROOF MOTOR
Refer to 5-1 [W16A0] as for removal and installation of
sunroof system.
B6M0353A
2. SUNROOF SWITCH
NOTE:
The sunroof switch is installed in spot light body.
1) Pry spot light lens off using a screwdriver.
2) Remove screws which secure spot light body.
3) Remove spot light body while disconnecting connec-
tors.
4) Remove screw which secures sunroof switch, and then
remove sunroof switch.
B6M0142A
B: INSPECTION
1. SUNROOF SWITCH
Set sunroof switch to each position and check continuity
between terminals as indicated in table below:
Terminal
Switch position43652
Open
Close
Tilt up
Tilt down
B6M0503
2. SUNROOF MOTOR
1) Apply battery voltage between 1-pin connector and
body ground wire.
2) Make sure that sunroof motor moves when connecting
terminals as described below:

Connect between terminals No. 3 and 4 (OPEN)

Connect between terminals No. 6 and 4 (CLOSE)

Connect between terminals No. 5 and 4 (TILT UP)

Connect between terminals No. 2 and 4 (TILT DOWN)
44
6-2SERVICE PROCEDURE
19. Sunroof

B6M0144A
3. SUNROOF RELAY
Check continuity between terminals as indicated in table
below, when battery voltage is applied between terminals
No. 1 and No. 3.
When current flows. Between terminals
No. 2 and No. 4Continuity exists.
When current does not flow. Between terminals
No. 2 and No. 4Continuity does not
exist.
Between terminals
No. 1 and No. 3Continuity exists.
B6M0354
20. Radio, Speaker and Antenna
A: REMOVAL AND INSTALLATION
1. RADIO BODY
1) Remove hand brake cover.
2) Remove console cover.
3) Remove screws which secure center panel. Remove
center panel.
B6M0355
4) Remove fitting screws, and slightly pull radio out of
instrument panel.
5) Disconnect connectors and antenna feeder cord.
B6M0146
2. FRONT SPEAKER
1) Remove gusset speaker from behind the rearview mir-
ror while disconnecting connector.
2) Remove door trim panel.
45
6-2SERVICE PROCEDURE
19. Sunroof - 20. Radio, Speaker and Antenna

B6M0144A
3. SUNROOF RELAY
Check continuity between terminals as indicated in table
below, when battery voltage is applied between terminals
No. 1 and No. 3.
When current flows. Between terminals
No. 2 and No. 4Continuity exists.
When current does not flow. Between terminals
No. 2 and No. 4Continuity does not
exist.
Between terminals
No. 1 and No. 3Continuity exists.
B6M0354
20. Radio, Speaker and Antenna
A: REMOVAL AND INSTALLATION
1. RADIO BODY
1) Remove hand brake cover.
2) Remove console cover.
3) Remove screws which secure center panel. Remove
center panel.
B6M0355
4) Remove fitting screws, and slightly pull radio out of
instrument panel.
5) Disconnect connectors and antenna feeder cord.
B6M0146
2. FRONT SPEAKER
1) Remove gusset speaker from behind the rearview mir-
ror while disconnecting connector.
2) Remove door trim panel.
45
6-2SERVICE PROCEDURE
19. Sunroof - 20. Radio, Speaker and Antenna