1999 SUBARU LEGACY roof

1. Specifications
A: 2200 cc MODEL
Lubrication methodForced lubrication
Oil pumpPump type Trochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter´thickness 78´9 mm (3.07´0.35 in)
Tip clearance between inner and outer rotorSTANDARD 0.04 Ð 0.14 mm (0.0016 Ð 0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and
pump caseSTANDARD 0.02 Ð 0.07 mm (0.0008 Ð 0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and
pump caseSTANDARD 0.10 Ð 0.175 mm (0.0039 Ð 0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80ÉC (176ÉF)700 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.2(4.4 US qt, 3.7 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 42.0(11.10 US gal, 9.24 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm
2, 71 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter´width 80´70 mm (3.15´2.76 in)
Oil filter to engine thread size M 20´1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7 kg/cm
2, 10 psi)
Oil pressure
switchType Immersed contact point type
Working voltage Ð wattage 12 V Ð 3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil pan capacity4.0(4.2 US qt, 3.5 Imp qt)
2
2-4[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Specifications

B: 2500 cc MODEL
Lubrication methodForced lubrication
Oil pumpPump type Trochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter´thickness 78´10 mm (3.07´0.39 in)
Tip clearance between inner and outer rotorSTANDARD 0.04 Ð 0.14 mm (0.0016 Ð 0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
caseSTANDARD 0.02 Ð 0.07 mm (0.0008 Ð 0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and
pump caseSTANDARD 0.10 Ð 0.175 mm (0.0039 Ð 0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80ÉC (176ÉF)600 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.6(4.9 US qt, 4.0 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 47.0(12.4 US gal, 10.3 Imp gal)/min.
Relief valve operation pressure 588 kPa (6.0 kg/cm
2, 85 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter´width 80´70 mm (3.15´2.76 in)
Oil filter to engine thread size M 20´1.5
Oil pressure
switchType Immersed contact point type
Working voltage Ð wattage 12 V Ð 3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil pan capacity4.5(4.8 US qt, 4.0 Imp qt)
3
[S1B0]2-4SPECIFICATIONS AND SERVICE DATA
1. Specifications

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

CAUTION:
Insert clips firmly and carefully by hand. To
avoid damaging clips, do not forcefully push or
hit clips.
2. SIDE PROTECTOR FRONT DOOR AND
REAR DOOR PORTIONS
1) Remove trim panel.
2) Use pliers to remove clips from inside of doors.
Remove them from vehicle body but keep them
with side protector.
NOTE:
Front door portion has five clips, rear door portion
has four clips.
3) Installation is in the reverse order of removal.
CAUTION:
Insert clips firmly and carefully by hand. To
avoid damaging clips, do not forcefully push or
hit clips.
NOTE:
To install side protector front door and rear door
portions, insert the first clip into the base hole [9
mm (0.35 in) dia.], and then insert other clips.
15. Roof Rail
A: REMOVAL AND INSTALLATION
1) Remove roof trim, rear quarter trim, pillar trim,
etc.
2) Remove flange bolts.
3) Remove flange nuts.
4) Remove roof rail.
B5M0304
5) 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.
57
[W15A0]5-1SERVICE PROCEDURE
15. Roof Rail

CAUTION:
Insert clips firmly and carefully by hand. To
avoid damaging clips, do not forcefully push or
hit clips.
2. SIDE PROTECTOR FRONT DOOR AND
REAR DOOR PORTIONS
1) Remove trim panel.
2) Use pliers to remove clips from inside of doors.
Remove them from vehicle body but keep them
with side protector.
NOTE:
Front door portion has five clips, rear door portion
has four clips.
3) Installation is in the reverse order of removal.
CAUTION:
Insert clips firmly and carefully by hand. To
avoid damaging clips, do not forcefully push or
hit clips.
NOTE:
To install side protector front door and rear door
portions, insert the first clip into the base hole [9
mm (0.35 in) dia.], and then insert other clips.
15. Roof Rail
A: REMOVAL AND INSTALLATION
1) Remove roof trim, rear quarter trim, pillar trim,
etc.
2) Remove flange bolts.
3) Remove flange nuts.
4) Remove roof rail.
B5M0304
5) 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.
57
[W15A0]5-1SERVICE PROCEDURE
15. Roof Rail

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