sunroof 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. 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

1. Sunroof
Entry of water into compartment(1) Check roof panel and glass lid assembly 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 glass lid assembly and roof panel for improper
clearance.
(2) Check sun shade 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.
67
[K100]5-1DIAGNOSTICS
1. Sunroof

20. Sunroof
A: REMOVAL AND INSTALLATION
1. SUNROOF AND SUNROOF MOTOR
as for removal and instal-
lation of sunroof system.
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
connectors.
4) Remove screw which secures sunroof switch,
and then remove sunroof switch.
B6M0141A
5) Installation is in the reverse order of removal.
B: INSPECTION
1. SUNROOF SWITCH
Set sunroof switch to each position and check con-
tinuity between terminals as indicated in table
below:
B6M0142A
B6M0861A
37
[W20B1]6-2SERVICE PROCEDURE
20. Sunroof

2. SUNROOF MOTOR
1) Apply battery voltage between 1-pin connector
(Except OUTBACK) or terminal No. 1 (OUTBACK)
and body ground wire.
2) Make sure that sunroof motor moves when con-
necting terminals as described below:
Except OUTBACK
IConnect between terminals No. 3 and 4 (OPEN)
IConnect between terminals No. 6 and 4
(CLOSE)
IConnect between terminals No. 5 and 4 (TILT
UP)
IConnect between terminals No. 2 and 4 (TILT
DOWN)
OUTBACK (Rear)
IConnect between terminals No. 2 and 3 (OPEN)
IConnect between terminals No. 6 and 3
(CLOSE)
B6M0893A
OUTBACK (Front)
IConnect between terminals No. 1 and 2 (TILT
UP)
IConnect between terminals No. 2 and 1 (TILT
DOWN)
B6M0788B
3. SUNROOF RELAY
Check continuity between terminals as indicated in
table below, when battery voltage is applied
between terminals No. 1 and No. 2.
When current
flows.Between terminals
No. 3 and No. 4Continuity exists.
When current
does not flow.Between terminals
No. 3 and No. 4Continuity does not
exist.
Between terminals
No. 1 and No. 2Continuity exists.
B6M0785A
38
6-2[W20B2]SERVICE PROCEDURE
20. Sunroof

IEach connector number shown in the wiring dia-
gram corresponds to that in the wiring harness.
The location of each connector in the actual
vehicle is determined by reading the first character
of the connector (for example, a ªFº for F8, ªiº for
i16, etc.) and the type of wiring harness.
The first character of each connector number
refers to the area or system of the vehicle.
Symbol Wiring harness and Cord
F Front wiring harness
B Bulkhead wiring harness
E Engine wiring harness
T Transmission cord
DDoor cord LH & RH, Rear
gate cord
IInstrument panel wiring har-
ness
RRear wiring harness, Rear
defogger cord
Room light cord,
Fuel tank cord,
Sunroof cord,
Trunk lid cord
P Floor wiring harness
G6M0205
2. Basic Diagnostics
Procedures
A: BASIC PROCEDURE
1. GENERAL
The most important purpose of diagnostics is to
determine which part is malfunctioning quickly, to
save time and labor.
2. IDENTIFICATION OF TROUBLE
SYMPTOM
Determine what the problem is based on the symp-
tom.
3. PROBABLE CAUSE OF TROUBLE
Look at the wiring diagram and check the system's
circuit. Then check the switch, relay, fuse, ground,
etc.
4. LOCATION AND REPAIR OF TROUBLE
1) Using the diagnostics narrow down the causes.
2) If necessary, use a voltmeter, ohmmeter, etc.
3) Before replacing certain component parts
(switch, relay, etc.), check the power supply,
ground, for open wiring harness, poor connectors,
etc. If no problems are encountered, check the
component parts.
5. CONFIRMATION OF SYSTEM
OPERATION
After repairing, ensure that the system operates
properly.
B: INSPECTION
1. VOLTAGE MEASUREMENT
1) Using a voltmeter, connect the negative lead to
a good ground point or negative battery terminal
and the positive lead to the connector or compo-
nent terminal.
2) Contact the positive probe of the voltmeter on
connector (A).
The voltmeter will indicate a voltage.
6
6-3[D2A1]WIRING DIAGRAM
2. Basic Diagnostics Procedures