1999 SUBARU LEGACY Service Repair Manual

1. Precaution
A: SUPPLEMENTAL RESTRAINT
SYSTEM ªAIRBAGº
Airbag system wiring harness is routed on and
along body panels.
CAUTION:
IAll Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
IBe careful not to damage Airbag system wir-
ing harness when repairing the body panel.
2
5-1[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Precaution

2. Body Datum Points
Various master repair locations are established as datum points used during body repairs. In addition, guide
holes, locators and indents are provided to facilitate panel replacement and achieve alignment accuracy.
NOTE:
Left and right datum points are all symmetrical to each other.
A: ENGINE COMPARTMENT AND ROOM
B5M0187B
(0) Cowl panel weather attaching
hole 6 mm (0.24 in) dia.
(1) Hood hinge front attaching hole
M8
(2) Strut mount attaching hole (Front
center) 9.5 mm (0.374 in) dia.
(3) Front fender attaching hole (Tip)
M6
(4) Rear upper surface of front side
frame 12 mm (0.47 in) dia.
(5) Middle upper surface of front
side frame 20 mm (0.79 in) dia.
(6) Front side frame front upper sur-
face 14´16 mm (0.55´0.63 in)
dia. oblong hole
(7) Side frame of front side frame 12
mm (0.47 in) dia.
(8) Headlight attaching hole at radia-
tor side panel 6.2´9 mm (0.244
´0.35 in) dia.
(9) Radiator panel side (LWR)
gauge hole 23 mm (0.91 in) dia.(23) Rear strut mount attaching hole
(Side) 10 mm (0.39 in) dia.
(24) Rear strut mount attaching hole
(Center) 12 mm (0.47 in) (0.244
´0.35 in) dia.
(25) Radiator panel (UPR) middle
hole 6 mm (0.24 in) dia.
(26) Front fender attaching hole at
radiator panel side M6
(27) Front fender attaching hole at
front pillar lower portion M6
(28) Hinge middle hole at front pillar
center 10 mm (0.39 in) dia.
(29) Front fender attaching hole at
front pillar center portion M6
(30) Retainer attaching square hole
at front pillar 7´7 mm (0.28´
0.28 in)
(31) Retainer attaching hole at center
pillar (Front) 3.5 mm (0.138 in)
dia.(32) Retainer attaching hole at center
pillar (Rear) 3.5 mm (0.138 in)
dia.
(33) Lower side of rear door hinge
M8
(34) Center pillar (LWR) gauge hole
27 mm (1.06 in) dia.
(35) Rear quarter outer corner patch
attaching hole 5.2 mm (0.205 in)
dia.
(39) Front rail center notch
(40) Front glass upper locating notch
RH: 6.5 mm (0.256 in) dia., LH:
6.5´10 mm (0.256´0.39 in)
dia. oblong hole
(41) Stud bolt lower locating notch
(48) Front center of rear floor pan 8
mm (0.31 in) dia.
(51) Front upper pillar (Inner) 7 mm
(0.28 in) dia.
3
[S2A0]5-1SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points

(52) Front seat belt adjust plate
attaching hole 12 mm (0.47 in)
dia.
(53) Rear door hinge middle hole 10
mm (0.39 in) dia.(54) Rear floor, near door 8 mm (0.31
in) dia.
(55) Trim upper attaching hole at 6
light 8 mm (0.31 in) dia.(56) Trim lower attaching hole at 6
light 8 mm (0.31 in) dia.
(58) Rear floor, near floor strut 15´
20 mm (0.59´0.79 in) dia.
oblong hole
4
5-1[S2A0]SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points

B: LUGGAGE COMPARTMENT AND ROOM
1. SEDAN
B5M0188B
(36) 6 light upper retainer attaching
square hole 7´7 mm (0.28´
0.28 in)
(42) Rear rail center notch
(43) Rear glass upper locating hole
RH: 6.5 mm (0.256 in) dia., LH:
6.5´10 mm (0.256´0.39 in)
dia. oblong hole
(44) Rear glass molding attaching
square hole 8´8 mm (0.31´
0.31 in)(45) Rear panel drain locater concave
part
(46) Front panel gauge hole 10 mm
(0.39 in) dia.
(47) Tunnel center M8
(59) Rear bumper attaching hole 45
mm (1.77 in) dia.
(65) Rear wiper attaching hole M6
(66) Trim attaching hole at rear skirt
(UPR) 7 mm (0.28 in) dia.(67) Rear bumper side attaching hole
6 mm (0.24 in) dia.
(68) Rear combination light mounting
hole 8 mm (0.31 in) dia.
(69) Rear bumper beam attaching
hole RH: 8 mm (0.31 in) dia.,
LH: 8´12 mm (0.31´0.47 in)
dia. oblong hole
5
[S2B1]5-1SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points

2. WAGON
B5M0189B
(37) D pillar cover attaching hole 12´
8 mm (0.47´0.31 in) dia.
(38) Shoulder mole attaching hole 8
mm (0.31 in) dia.
(49) Front pillar (LWR) gauge hole 10
mm (0.39 in) dia. (On both
Sedan and Wagon)
(50) Front pillar (UPR) gauge hole 16
mm (0.63 in) dia. (On both
Sedan and Wagon)(57) Retainer attaching square hole
at C pillar (UPR) 7´7 mm (0.28
´0.28 in)
(60) Trim attaching hole at rear skirt
(UPR) 15 mm (0.59 in) dia.
(61) Rear bumper side attaching hole
6 mm (0.24 in) dia.
(62) Rear seat belt bolt hole 13 mm
(0.51 in) dia.
(63) Rear rail locator concave part(64) Buffer attaching hole (UPR) M6
(70) Rear quarter end (LWR) gauge
hole 20 mm (0.79 in) dia.
(71) Rear combination light mounting
hole 7 mm (0.28 in) dia.
6
5-1[S2B2]SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points

C: UNDERBODY
B5M0190B
(10) Radiator panel (LWR) frame
gauge hole 10 mm (0.39 in) dia.
(11) Front side frame front lower sur-
face 20 mm (0.79 in) dia.
(12) Front side frame center lower
surface 20 mm (0.79 in) dia.
(13) Front suspension attaching hole
M14
(14) Suspension attaching bracket
M14(15) Front side frame rear lower cen-
ter surface 20 mm (0.79 in) dia.
(16) Transmission mount attaching
hole M10
(17) Front side frame rear lower sur-
face 15 mm (0.59 in) dia.
(18) Rear frame front M12
(19) Rear frame front hole 25 mm
(0.98 in) dia.(20) Rear crossmember attaching
hole M12
(21) Rear frame center hole 7 mm
(0.28 in) dia.
(22) Rear frame rear concave part 15
mm (0.59 in) dia.
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[S2C0]5-1SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points

D: DATUM POINT LOCATION
B5M0191BB5M0192B
B5M0193BB5M0194B
B5M0195BB5M0196B
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5-1[S2D0]SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points

B5M0197BB5M0198B
B5M0199BB5M0200B
B5M0201BB5M0202B
B5M0203BB5M0204B
9
[S2D0]5-1SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points