1999 SUBARU LEGACY 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

6. Steering Support Beam
B5M0264B
(1) Bracket
(2) Steering beamTightening torque: N´m (kg-m, ft-lb)
T:
32±10 (3.3±1.0, 23.9±7)
35
[C600]5-1COMPONENT PARTS
6. Steering Support Beam

7. Guard Pipe
B5M0371B
(1) Guard pipe
(2) Rear floor panelTightening torque: N´m (kg-m, ft-lb)
T:
32±10 (3.3±1.0, 23.9±7)
36
5-1[C700]COMPONENT PARTS
7. Guard Pipe

1. Hood
A: REMOVAL AND INSTALLATION
NOTE:
The hood lock has a dual locking design which
consists of a main lock and a safety lock mecha-
nism. When the release knob located at the front
pillar on the driver's side is pulled back, the main
lock is released through the cable attached to the
knob.
The safety lock can be released by pushing the
lever protruding above the front grill while opening
the hood.
1. HOOD
1) Open front hood, and remove washer hose.
2) Remove attaching bolts.
G5M0137
3) Detach front hood from hinges.
4) Installation is in the reverse order of removal.
CAUTION:
With buffer protruding about 18 mm (0.71 in)
beyond radiator panel, make sure that:
INo clearance exists between buffer and
inner hood.
IHood main lock is applied when hood is
released at a height of approximately 10 mm
(0.39 in) above the closed position.
NOTE:
Align the center of striker with lock during installa-
tion. Make sure safety lever is properly caught by
striker under the hood's own weight.
G5M0141
2. HOOD LOCK
1) Open front hood and remove front grille.
2) Remove bolts which secure lock assembly to
radiator panel, and remove lock assembly.
B5M0267
3) Disconnect release cable from lock assembly.
4) Installation is in the reverse order of removal.
NOTE:
IRoute hood lock release cable and hold with
clips.
IAfter installing release cable, ensure it operates
smoothly.
IApply grease to sliding surfaces of parts.
G5M0142
3. RELEASE CABLE
1) Remove front grille.
2) Remove release cable from opener lever in
passenger compartment.
3) Remove release cable from lock assembly.
B5M0319
4) Remove cable clip from engine compartment.
5) Installation is in the reverse order of removal.
37
[W1A3]5-1SERVICE PROCEDURE
1. Hood

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