SUBARU LEGACY 1999 Service Repair Manual

4. HOOD DUCT
1) Open front hood.
2) Remove attaching tapping screws and screw
rivet, then remove hood inner.
3) Remove attaching nuts, then remove hood
duct.
B5M0465A
4) Installation is in the reverse order of removal.
B: POINTS TO CHECK
1) Check striker for bending or abnormal wear.
2) Check safety lever for improper movement.
3) Check other levers and spring for rust formation
and unsmooth movement.
G5M0140
C: ADJUSTMENT
1) Fore-aft and left-right adjustments
Loosen striker mounting bolts and adjust fore-and-
aft position of striker.
CAUTION:
Do not adjust striker position using the lock.
Doing so may result in a misaligned front grille.
B5M0268A
2) Up-down adjustment
Make up-and-down adjustment of striker only
when hood does not properly contact buffer or
hood is not flush with fender, or when release cable
does not properly operate. Adjustment can be
made by adjusting the stroke length of striker after
lock assembly mounting screws are removed.
38
5-1[W1A4]SERVICE PROCEDURE
1. Hood

2. Trunk Lid
A: REMOVAL AND INSTALLATION
1. TRUNK LID
1) Open trunk lid.
2) Remove trunk lid mounting bolts and detach
trunk lid from hinges.
G5M0144
3) Installation is in the reverse order of removal.
2. TORSION BAR
1) Open trunk lid. Remove torsion bars from hinge
links using ST.
ST 927780000 REMOVER
CAUTION:
Be careful because torsion bar quickly swings
back when released.
G5M0145
2) Remove the left and right torsion bars.
WARNING:
Be careful because trunk lid drops under its
own weight when torsion bars are removed.
3) Installation is in the reverse order of removal.
NOTE:
Apply a coat of grease to the rotary section of
hinges and contact surfaces of torsion bars.
3. TRUNK LID LOCK ASSEMBLY AND
KEY CYLINDER
1) Remove rod of lock assembly from rod holder
of key lock assembly.
G5M0146
2) Remove nuts which hold lock assembly and
remove lock assembly.
NOTE:
IAlways remove rear skirt trim panel beforehand,
if so equipped.
IBe careful not to bend opener cable.
3) Remove rod holder and detach key cylinder
from trunk lid.
B5M0269A
4) Installation is in the reverse order of removal.
NOTE:
Apply grease to sliding surfaces of lock assembly
and striker.
B5M0372A
39
[W2A3]5-1SERVICE PROCEDURE
2. Trunk Lid

4. TRUNK LID OPENER
1) Remove rear seats, center pillar lower cover,
floor mat, rear arch cover and side sill cover (on the
driver's side).
2) Remove all clips which hold cable.
3) Disconnect cable from pull handle assembly.
4) Remove bolts and detach pull handle assembly.
5) Loosen bolts which hold lock assembly, and
remove it.
6) Remove striker from trunk lid.
G5M0147
7) Disconnect cable from striker.
NOTE:
IBe careful not to bend or break cable.
IBasic model vehicles do not have trunk lid
opener system.
8) Installation is in the reverse order of removal.
CAUTION:
IWhen installing cover to pull handle
assembly, observe the following:
IBe careful not to catch harness.
IEngage pull handle assembly pawls
firmly.
NOTE:
After installing opener cable, ensure it moves
smoothly.
B: ADJUSTMENT
1. TRUNK LID
1) To adjust left-right lid positioning, loosen bolts
which hold trunk lid to hinges.2) To adjust up-down lid alignment, place wash-
er(s) between trunk lid and hinges or move trunk
lock assembly up or down.
B5M0270A
40
5-1[W2A4]SERVICE PROCEDURE
2. Trunk Lid

3. Fuel Flap
A: REMOVAL AND INSTALLATION
1. FUEL FLAP
1) Remove bolts which hold hinge to fuel flap, and
detach fuel flap.
B5M0373
2) Installation is in the reverse order of removal.
CAUTION:
Make sure the clearance between fuel flap and
vehicle body is equal at all points.
2. FUEL FLAP OPENER
1) Remove rear seats, center pillar lower cover,
floor mat, rear arch cover/rear quarter trim
(Wagon), and side sill cover (on the driver's side).
2) Remove all clips which hold cable.
3) Disconnect cable from pull handle.
B5M0374A
4) Detach pull handle by removing bolts.
5) Detach fuel lock holder by turning it.
6) Installation is in the reverse order of removal.
CAUTION:
IWhen installing cover to pull handle
assembly, observe the following:
IBe careful not to catch harness.
IEngage pull handle assembly pawls
firmly.
IAfter installing opener cable, ensure it
moves smoothly.
4. Front Bumper
A: REMOVAL AND INSTALLATION
1. EXCEPT OUTBACK MODEL
1) Disconnect the ground cable from the battery.
2) Remove two bolts from lower center of bumper.
B5M0273
3) Remove mud guard.
NOTE:
It is not necessary to remove the entire mud guard.
Remove clips from the front section of mud guard,
if necessary.
4) Remove the canister.
5) Remove two bolts from side of bumper.
B5M0274
6) Remove front grill.
7) Remove headlight.
8) Remove clips from both sides of front bumper.
NOTE:
When removing, push the pin at the center of clip
with a thin screwdriver.
B5M0376
41
[W4A1]5-1SERVICE PROCEDURE
4. Front Bumper

3. Fuel Flap
A: REMOVAL AND INSTALLATION
1. FUEL FLAP
1) Remove bolts which hold hinge to fuel flap, and
detach fuel flap.
B5M0373
2) Installation is in the reverse order of removal.
CAUTION:
Make sure the clearance between fuel flap and
vehicle body is equal at all points.
2. FUEL FLAP OPENER
1) Remove rear seats, center pillar lower cover,
floor mat, rear arch cover/rear quarter trim
(Wagon), and side sill cover (on the driver's side).
2) Remove all clips which hold cable.
3) Disconnect cable from pull handle.
B5M0374A
4) Detach pull handle by removing bolts.
5) Detach fuel lock holder by turning it.
6) Installation is in the reverse order of removal.
CAUTION:
IWhen installing cover to pull handle
assembly, observe the following:
IBe careful not to catch harness.
IEngage pull handle assembly pawls
firmly.
IAfter installing opener cable, ensure it
moves smoothly.
4. Front Bumper
A: REMOVAL AND INSTALLATION
1. EXCEPT OUTBACK MODEL
1) Disconnect the ground cable from the battery.
2) Remove two bolts from lower center of bumper.
B5M0273
3) Remove mud guard.
NOTE:
It is not necessary to remove the entire mud guard.
Remove clips from the front section of mud guard,
if necessary.
4) Remove the canister.
5) Remove two bolts from side of bumper.
B5M0274
6) Remove front grill.
7) Remove headlight.
8) Remove clips from both sides of front bumper.
NOTE:
When removing, push the pin at the center of clip
with a thin screwdriver.
B5M0376
41
[W4A1]5-1SERVICE PROCEDURE
4. Front Bumper

9) Remove bolts (engine compartment side) from
bumper stays.
B5M0275
10) Remove front bumper assembly.
NOTE:
Front bumper surface is accessible for removal
after removing the following parts:
Two bolts (on the lower center of bumper), mud
guard, bolts (on the side of bumper), front grille,
headlight, clips (on both sides of front bumper),
clips (on the upper section of bumper), and clips
(on the lower section of bumper).
B5M0276
11) Installation is in the reverse order of removal.CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing the bumper.
IWhen installing canister, insert air vent hose
of canister into the hole on body.
ITo facilitate installation of front bumper,
insert the protrusion inside bumper into the
groove of body.
B5M0375A
2. OUTBACK MODEL
1) Disconnect the ground cable from the battery.
G6M0095
2) Remove two bolts from lower center of bumper.
B5M0273
3) Remove mud guard.
NOTE:
It is not necessary to remove the entire mud guard.
Remove clips from the front section of mud guard,
if necessary.
4) Remove the canister.
42
5-1[W4A2]SERVICE PROCEDURE
4. Front Bumper

5) Remove two bolts from side of bumper.
B5M0274
6) Remove front grill.
7) Remove headlight.
8) Remove fog lamps.
9) Remove clips from both sides of front bumper.
NOTE:
When removing, push the pin at the center of clip
with a thin screwdriver.
B5M0376
10) Remove bolts (engine compartment side) from
bumper stays.
B5M0275
11) Remove front bumper assembly.
NOTE:
Front bumper surface is accessible for removal
after removing the following parts:
Two bolts (on the lower center of bumper), mud
guard, bolts (on the side of bumper), front grille,
headlight, clips (on both sides of front bumper),
clips (on the upper section of bumper), and clips
(on the lower section of bumper).
B5M0406
12) Installation is in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing the bumper.
IWhen installing canister, insert air vent hose
of canister into the hole on body.
ITo facilitate installation of front bumper,
insert the protrusion inside bumper into the
groove of body.
B5M0375A
43
[W4A2]5-1SERVICE PROCEDURE
4. Front Bumper

5. Rear Bumper
A: REMOVAL AND INSTALLATION
1. SEDAN
1) Remove one bolt and one clip from side of
bumper.
B5M0377
2) Open trunk lid. Remove trunk trim panel clips
and detach trim.
3) Remove rear bumper beam (upper) attaching
nut.
4) Remove bolts from bumper stays.
B5M0378
5) Remove rear bumper assembly.
B5M0280
6) Installation is in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.ITo facilitate installation of rear bumper,
attach slider to the guide pin.
B5M0283A
B5M0284A
ITo facilitate installation of rear bumper,
insert the bumper hook into the body groove.
B5M0380A
2. WAGON
1) Remove one bolt and one clip from side of
bumper.
B5M0377
2) Open rear gate. Remove rear quarter trim lid.
44
5-1[W5A1]SERVICE PROCEDURE
5. Rear Bumper

3) Remove two clips from lower center of bumper.
B5M0379
4) Remove bolts from bumper stays.
B5M0281
5) Remove rear bumper assembly.
B5M0282
6) Installation is in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.ITo facilitate installation of rear bumper,
attach slider to the guide pin.
B5M0283A
B5M0284A
ITo facilitate installation of rear bumper,
insert the bumper hook into the body groove.
B5M0380A
3. OUTBACK MODEL
1) Remove one clip from side of bumper.
B5M0407
2) Open rear gate and remove rear quarter trim
lid.
45
[W5A3]5-1SERVICE PROCEDURE
5. Rear Bumper

3) Remove five bolts from lower center of bumper.
B5M0408
4) Remove bolts from bumper stays.
B5M0409
5) Remove rear bumper assembly.
B5M0282
6) Installation is in the reverse order of removal.
CAUTION:
IBe extremely careful to prevent scratches on
bumper face as it is made of resin.
IBe careful not to scratch the body when
removing or installing bumper.ITo facilitate installation of rear bumper,
attach slider to the guide pin.
B5M0283A
B5M0284A
ITo facilitate installation of rear bumper,
insert the bumper hook into the body groove.
B5M0380A
46
5-1[W5A3]SERVICE PROCEDURE
5. Rear Bumper