roof rack SUBARU LEGACY 1999 Service Repair Manual

5. Sunroof
B5M0481B
(1) Sunroof panel
(2) Motor cover
(3) Motor ASSY
(4) Tilt up ASSY
(5) Control module ASSY
(6) Frame ASSY
(7) Sunroof trim
(8) Weatherstrip(9) Sunroof panel
(10) Deflector and guide rail ASSY
(11) Guide rail cover
(12) Frame ASSY
(13) Motor ASSY
(14) Drain ASSY
(15) Sunroof trim
(16) Drain tube(17) Garnish (Sedan only)
(18) Set bracket
Tightening torque: N´m (kg-m, ft-lb)
T:
7.4±2.0 (0.75±0.2, 5.4±1.4)
34
5-1[C500]COMPONENT PARTS
5. Sunroof

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. 5-3 [W5A3].>
(2) Remove front pillar trim upper. [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.
(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. [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. [W16A2].>
(2) Remove roof trim panel. [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. [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) Increase the upward travel of window glass up
to the position where upper edge just touches
weatherstrip surface with door closed.
G5M0511
3) After adjustment, temporarily tighten stoppers.
NOTE:
Make sure that each glass stopper is touched.
IRemedy for incorrect contact of door
glass to weatherstrip
1) Close front door and raise door glass.
2) If clearance is below specifications, loosen bolt
(A) and bolt (B).
3) If clearance is over specifications, tighten bolt
(A) and bolt (B).
B5M0076A
IFit adjustment
Door glass fit is adjusted by displacing the glass
front edge with a stabilizer.
NOTE:
Before adjusting glass fit, visually check to deter-
mine relative adjusting positions of retainer and
molding (on roof side) and glass surface.1) Alternately adjust two rear sash adjusting bolts
(A) until dimensions (indicated in figure) are
obtained.
B5M0076A
CAUTION:
Do not loosen two adjusting nuts (A) at the
same time, as this moves sash fore and aft,
creating unequal glass- to-sash clearance. Dur-
ing adjustment, loosen only one nut and keep
the other tightened.
NOTE:
Always adjust two rear sash adjusting bolts (A) by
the same amount. Do not adjust the adjusting bolts
with sash bracket inclined toward inner panel, as
this increases effort required to operate regulator.
B5M0077A
2) Adjust front sash fit using rear sash adjustment
procedure outlined above as a guide. Two adjust-
ing bolts must be adjusted by the same amount.
NOTE:
Front and rear sash adjustment procedures are
basically the same; however, the amount of adjust-
ment is not always the same due to alignment dis-
persion of individual doors.
Adjust front and rear sash fit, as equally as pos-
sible. Otherwise, effort required to operate regula-
tor may increase.
3) After adjusting front sash-to-glass fit, secure
front sash.
23
[W2B4]5-2SERVICE PROCEDURE
2. Door